High flow, high heat polycarbonate compositions

ABSTRACT

Polycarbonate blend compositions are disclosed. The compositions include at least one polycarbonate useful for high heat applications. The compositions include at least one poly(aliphatic ester)-polycarbonate. The compositions can include one or more additional polymers. The compositions can include one or more additives. The compositions can be used to prepare articles of manufacture.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national stage application of PCT/US2015/040878 filed Jul. 17, 2015, which claims priority to U.S. Provisional Application No. 62/025,926 filed Jul. 17, 2014, both of which are hereby incorporated by reference in their entirety.

This application claims priority to U.S. Provisional Application No. 62/025,926, filed Jul. 17, 2014, which is herein incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to polycarbonate compositions, methods of using the compositions, and processes for preparing the compositions. In particular, the disclosure relates to polycarbonate compositions having improved thermal, mechanical, rheological or flame retardant properties. The disclosure also relates to articles comprising the polycarbonate compositions.

BACKGROUND

Polycarbonates (PC) are synthetic thermoplastic resins that can be derived from bisphenols and phosgenes by interfacial polymerization, or from bisphenols and diaryl carbonates by melt polymerization. Polycarbonates are a useful class of polymers having many desired properties. They are highly regarded for optical clarity and enhanced impact strength and ductility at room temperature.

Since part designs are becoming more and more complex, a need remains for materials that have an improved balance of properties (e.g., heat resistance, melt flow, impact resistance, and metallizability). In particular, there remains a need for improved polycarbonate compositions, and articles formed from such compositions.

SUMMARY

In one aspect, disclosed is an article including a thermoplastic composition comprising: (a) a first polycarbonate; (b) a poly(aliphatic ester)-polycarbonate copolymer; and (c) optionally a second polycarbonate; wherein the composition has a heat deflection temperature of at least 120° C., measured at 1.8 megapascals (Mpa) in accordance with ASTM D 648; wherein the composition has a melt viscosity of less than 130 Pascals-seconds (Pa·s), measured in accordance with ISO 11443 at 316° C. at a shear rate of 5000 reciprocal seconds (s⁻¹).

The first polycarbonate includes structural units derived from at least one of:

wherein R^(a) and R^(b) at each occurrence are each independently halogen, C₁-C₁₂ alkyl, C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; p and q at each occurrence are each independently 0 to 4; R¹³ at each occurrence is independently a halogen or a C₁-C₆ alkyl group; c at each occurrence is independently 0 to 4; R¹⁴ at each occurrence is independently a C₁-C₆ alkyl, phenyl, or phenyl substituted with up to five halogens or C₁-C₆ alkyl groups; R^(g) at each occurrence is independently C₁-C₁₂ alkyl or halogen, or two R^(g) groups together with the carbon atoms to which they are attached form a four-, five, or six-membered cycloalkyl group; and t is 0 to 10.

The poly(aliphatic ester)-polycarbonate copolymer can have the formula:

wherein m is 4 to 18; x+y is 100; and R³ is formula (I) or formula (II):

wherein R^(h) is halogen, alkyl, or haloalkyl; n is 0 to 4; and X^(a) is formula (III) or formula (IV):

wherein R^(c) and R^(d) are each independently hydrogen, halogen, alkyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, or heteroarylalkyl; and R^(e) is a divalent alkyl group.

The second polycarbonate can be a Bisphenol A (BPA) polycarbonate having a weight average molecular weight of 17,000 to 40,000 grams per mole (g/mol), as determined by gel permeation chromatography (GPC) using BPA polycarbonate standards.

The compositions, methods, and processes are further described herein.

DETAILED DESCRIPTION

The present disclosure relates to polycarbonate-based blend compositions, also referred to herein as thermoplastic compositions. The compositions include at least one high heat polycarbonate and at least one poly(aliphatic ester)-polycarbonate copolymer. The compositions can include one or more additional polymers (e.g., homopolycarbonates, polysiloxane-polycarbonate copolymers, polyesters). The compositions can include one or more additives (e.g., fillers, mold release agents, antioxidants, flame retardants). The compositions can have improved thermal properties, mechanical properties, or rheological properties.

The compositions can comprise the combination of organophosphorus flame retardant, filler and anti-dripping agent (TSAN). This combination can be particularly useful in obtaining an article with surprisingly excellent flame retardant properties, while maintaining thermal, mechanical, and rheological properties.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present invention. All publications, patent applications, patents and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.

The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures. The singular forms “a.” “an” and “the” include plural references unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments “comprising,” “consisting of” and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.

The conjunctive term “or” includes any and all combinations of one or more listed elements associated by the conjunctive term. For example, the phrase “an apparatus comprising A or B” can refer to an apparatus including A where B is not present, an apparatus including B where A is not present, or an apparatus where both A and B are present. The phrases “at least one of A, B, . . . and N” or “at least one of A, B . . . . N, or combinations thereof” are defined in the broadest sense to mean one or more elements selected from the group comprising A, B, . . . and N, that is to say, any combination of one or more of the elements A, B, . . . or N including any one element alone or in combination with one or more of the other elements which can also include, in combination, additional like elements not listed.

The terms “first,” “second,” “third,” and the like, as used herein, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

“Alkyl” as used herein can mean a linear, branched, or cyclic hydrocarbyl group, such as a methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, tert-butyl group, n-pentyl group, isopentyl group, n-hexyl group, isohexyl group, cyclopentyl group, cyclohexyl group, and the like.

“Aryl” as used herein can mean a substituted or unsubstituted aryl radical containing from 6 to 36 ring carbon atoms. Examples of aryl include, but are not limited to, a phenyl group, a bicyclic hydrocarbon fused ring system, or a tricyclic hydrocarbon fused ring system wherein one or more of the rings are a phenyl group.

“Arylalkyl” as used herein can mean an aryl, as defined herein, appended to the parent molecular moiety through an alkyl, as defined herein.

“Copolymer” as used herein can mean a polymer derived from two or more monomeric species, as opposed to a homopolymer, which is derived from only one monomer.

“Glass Transition Temperature” or “Tg” as used herein can mean the maximum temperature that a polymer, such as a polycarbonate, will have one or more useful properties. These properties include impact resistance, stiffness, strength, and shape retention. The Tg of a polycarbonate therefore can be an indicator of its useful upper temperature limit, particularly in plastics applications.

The Tg of a polymer, such as a polycarbonate, can depend primarily on the composition of the polymer. Polycarbonates that are formed from monomers having more rigid and less flexible chemical structures than Bisphenol A (BPA) generally have higher Tgs than BPA polycarbonate, while polycarbonates that are formed from monomers having less rigid and more flexible chemical structures than BPA generally have lower Tgs than BPA polycarbonate. For example, a polycarbonate formed from 33 mole % of a rigid monomer, 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one (“PPPBP”), and 67 mole % BPA has a Tg of 198° C., while a polycarbonate formed from Bisphenol-A, but also having 6 wt % of siloxane units, a flexible monomer, has a Tg of 145° C. Mixing of two or more polycarbonates having different Tgs can result in a Tg value for the mixture that is intermediate between the Tgs of the polycarbonates that are mixed. The Tg of a polycarbonate can also be an indicator of the molding or extrusion temperatures required to form polycarbonate parts. The higher the Tg of the polycarbonate the higher the molding or extrusion temperatures that are needed to form polycarbonate parts.

The Tgs described herein are measures of heat resistance of, for example, polycarbonate and polycarbonate blends. The Tg can be determined by differential scanning calorimetry (DSC). The calorimetry method can use a TA Instruments Q1000 instrument, for example, with setting of 20° C./min ramp rate and 40° C. start temperature and 200° C. end temperature.

“Heteroaryl” as used herein can mean any aromatic heterocyclic ring which can comprise an optionally benzocondensed 5 or 6 membered heterocycle with from 1 to 3 heteroatoms selected among N, O or S. Non limiting examples of heteroaryl groups can include pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, indolyl, imidazolyl, thiazolyl, isothiazolyl, pyrrolyl, phenyl-pyrrolyl, furyl, phenyl-furyl, oxazolyl, isoxazotyl, pyrazolyl, thienyl, benzothienyl, isoindolinyl, benzoimidazolyl, quinolinyl, isoquinolinyl, 1,2,3-triazolyl, 1-phenyl-1,2,3-triazolyl, and the like.

“Polycarbonate” as used herein can mean an oligomer or polymer comprising residues of one or more polymer structural units, or monomers, joined by carbonate linkages.

Unless otherwise indicated, each of the foregoing groups can be unsubstituted or substituted, provided that the substitution does not significantly adversely affect synthesis, stability, or use of the compound.

“Thermal stability” as used herein refers to resistance of a polymer to molecular weight degradation under thermal conditions. Thus, a polymer with poor thermal stability can show significant molecular weight degradation under thermal conditions, such as during extrusion, molding, thermoforming, hot-pressing, and like conditions. Molecular weight degradation can also be manifest through color formation or in the degradation of other properties such as weatherability, gloss, mechanical properties, or thermal properties. Molecular weight degradation can also cause significant variation in processing conditions such as melt viscosity changes.

For the recitation of numeric ranges herein, each intervening number therebetween with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated.

Disclosed are polycarbonate-based blend compositions. The compositions include at least one high heat polycarbonate, which can be referred to herein as “the first polycarbonate.” The compositions include at least one poly(aliphatic ester)-polycarbonate copolymer. The compositions can include one or more additional polycarbonates, which can be referred to herein as “the second polycarbonate,” and the like. The compositions can include one or more polyesters, which can be referred to herein as “the first polyester,” “the second polyester,” and the like. The compositions can include one or more additives.

Polycarbonates of the disclosed blend compositions can be homopolycarbonates, copolymers comprising different moieties in the carbonate units (referred to as “copolycarbonates”), copolymers comprising carbonate units and other types of polymer units such as polysiloxane units, polyester units, and combinations thereof.

The polycarbonates can include identical or different repeating units derived from one or more monomers (e.g. a second, third, fourth, fifth, sixth, etc., other monomer compound). The monomers of the polycarbonate can be randomly incorporated into the polycarbonate. For example, a polycarbonate copolymer can be arranged in an alternating sequence following a statistical distribution, which is independent of the mole ratio of the structural units present in the polymer chain. A random polycarbonate copolymer can have a structure, which can be indicated by the presence of several block sequences (I-I) and (O-O) and alternate sequences (I-O) or (O-I), that follow a statistical distribution. In a random x:(1−x) copolymer, wherein x is the mole percent of a first monomer(s) and 1−x is the mole percent of the monomers, one can calculate the distribution of each monomer using peak area values determined by ¹³C nuclear magnetic resonance (NMR) spectroscopy, for example.

A polycarbonate copolymer can have alternating I and O units (-I-O-I-O-I-O-I-O-), or I and O units arranged in a repeating sequence (e.g. a periodic copolymer having the formula: (I-O-I-O-O-I-I-I-I-O-O-O)n). The polycarbonate copolymer can be a statistical copolymer in which the sequence of monomer residues follows a statistical rule. For example, if the probability of finding a given type monomer residue at a particular point in the chain is equal to the mole fraction of that monomer residue in the chain, then the polymer can be referred to as a truly random copolymer. The polycarbonate copolymer can be a block copolymer that comprises two or more homopolymer subunits linked by covalent bonds (-I-I-I-I-I-O-O-O-O-O-). The union of the homopolymer subunits can require an intermediate non-repeating subunit, known as a junction block. Block copolymers with two or three distinct blocks are called diblock copolymers and triblock copolymers, respectively.

The polycarbonates can include any suitable mole percent (mol %) of selected monomer units. The polymers can comprise 1 to 99.5 mol %, 5 to 95 mol %, 10 to 90 mol %, 15 to 85 mol %, 20 to 80 mol %, 25 to 75 mol %, 30 to 70 mol %, 3% to 65 mol %, 40 to 60 mol %, or 45 to 55 mol % of a selected monomer unit.

The polycarbonates can have a Tg of greater than or equal to 120° C., greater than or equal to 125° C., greater than or equal to 130° C., greater than or equal to 135° C., greater than or equal to 14° C., greater than or equal to 145° C., greater than or equal to 150° C., greater than or equal to 155° C., greater than or equal to 160° C., greater than or equal to 165° C., greater than or equal to 170° C., greater than or equal to 175° C., greater than or equal to 180° C., greater than or equal to 185° C., greater than or equal to 190° C., greater than or equal to 200° C., greater than or equal to 210° C., greater than or equal to 220° C., greater than or equal to 230° C., greater than or equal to 24° C., greater than or equal to 250° C., greater than or equal to 260° C., greater than or equal to 270° C., greater than or equal to 280° C., greater than or equal to 290° C., or greater than or equal to 300° C., as measured using a differential scanning calorimetry method. In any of the foregoing embodiments, the Tg of the polycarbonate can be less than 500° C., or less than 450° C., or less than 400° C., or less than 380° C. In some embodiments the Tg of the polycarbonates is 150° C. to 380° C.

The polycarbonates can have a weight average molecular weight (Mw) of 1,500 to 150,000 Daltons (Da) [^(±)1,000 Da], 10,000 to 50,000 Da [^(±)1,000 Da], 15,000 to 35,000 Da [^(±)1,000 Da], or 20,000 to 30,000 Da [^(±)1,000 Da]. In certain embodiments, the polycarbonates have weight average molecular weights of 15,000 Da [^(±)1,000 Da], 16,000 Da [^(±)1,000 Da], 17,000 Da [^(±)1,000 Da], 18,000 Da [^(±)1,000 Da], 19,000 Da [^(±)1,000 Da], 20,000 Da [^(±)1,000 Da], 21,000 Da [^(±)1,000 Da], 22,000 Da [^(±)1,000 Da], 23,000 Da [^(±)1,000 Da], 24,000 Da [^(±)1,000 Da], 25,000 Da [^(±)1,000 Da], 26,000 Da [^(±)1,000 Da], 27,000 Da [^(±)1,000 Da], 28,000 Da [^(±)1,000 Da], 29,000 Da [^(±)1,000 Da], 30,000 Da [^(±)1,000 Da], 31,000 Da [^(±)1,000 Da], 32,000 Da [^(±)1,000 Da], 33,000 Da [^(±)1,000 Da], 34,000 Da [1,000 Da], or 35,000 Da [^(±)1,000 Da]. In any of the foregoing embodiments, the Mw of the polycarbonate can be less than 100,000 Da, or less than 75,000 Da, or less than 50,000 Da. In some embodiments the Mw of the polycarbonates can be 15,000 to 50,000 Da. Molecular weight determinations can be performed using gel permeation chromatography (GPC), using a cross-linked styrene-divinylbenzene column and calibrated to polycarbonate references using a UV-VIS detector set at 254 nm. Samples can be prepared at a concentration of 1 mg/ml, and eluted at a flow rate of 1.0 ml/min.

The polycarbonates can have a polydispersity index (PDI) of 1.0 to 10.0, 2.0 to 7.0, or 2.0 to 6.0. In certain embodiments, the polycarbonates have PDIs of 2.50, 3.00, 3.50, 4.00, 4.50, 5.00, 5.50, 6.00, 6.50, 7.00, or 7.50. In certain embodiments, the polycarbonates have a PDI of 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3.0. In certain embodiments, the polycarbonates have a PDI of 2.2 or 2.3.

The polycarbonates can have a biocontent of 2 to 90 weight percent (wt %); 5 to 25 wt %; 10 to 30 wt %; 15 to 35 wt %; 20 to 40 wt %; 25 to 45 wt %; 30 to 50 wt %; 35 to 55 wt %; 40 to 60 wt %; 45 to 65 wt %; 55 to 70% wt %; 60 to 75 wt %; 50 to 80 wt %; or 50 to 90 wt %. The biocontent can be measured according to ASTM D6866.

The term “polycarbonate” and “polycarbonate resin” refers to compositions having repeating units of formula (1):

wherein each R¹⁰⁰ can independently comprise any suitable organic group, such as an aliphatic, alicyclic, or aromatic group, or any combination thereof. In certain embodiments certain embodiments, R¹⁰⁰ in the carbonate units of formula (1) can be a C₆-C₃₆ aromatic group wherein at least one moiety is aromatic.

The repeating units of formula (1) can be derived from dihydroxy compounds of formula (2): HO—R¹⁰⁰—OH  (2) wherein R¹⁰⁰ is as defined above.

The polycarbonate can include repeating units of formula (3):

wherein each of the A¹ and A² is a monocyclic divalent aryl group and Y¹ is a bridging group having one or two atoms that separate A¹ and A². For example, one atom can separate A¹ from A², with illustrative examples of these groups including —O—, —S—, —S(O)—, —S(O)₂—, —C(O)—, methylene, cyclohexyl-methylene, 2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecyclidene, cyclododecylidene, and adamantylidene. The bridging group of Y¹ can be a hydrocarbon group such as methylene, cyclohexylidene, or isopropylidene.

The repeating units of formula (3) can be derived from a dihydroxy monomer of formula (4): HO-A¹-Y¹-A²-OH  (4) wherein A¹, A², and Y¹ are as defined above.

The polycarbonate can include repeating units of formula (5):

wherein R^(a) and R^(b) are each independently halogen, C₁-C₁₂ alkyl, C₁-C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; p and q are each independently 0 to 4; and X^(a) is a bridging group between the two arylene groups. X^(a) can be a single bond. —O—, —S—, —S(O)—, —S(O)₂—, —C(O)—, or a C₁-C₁₈ organic group. The C₁-C₁₈ organic bridging group can be cyclic or acyclic, aromatic or non-aromatic, and can optionally include halogens, heteroatoms (e.g., oxygen, nitrogen, sulfur, silicon, or phosphorous), or a combination thereof. The C₁-C₁₈ organic group can be disposed such that the C₆ arylene groups connected thereto are each connected to a common alkylidene carbon or to different carbons of the C₁-C₁₈ organic bridging group. The bridging group X^(a) and the carbonate oxygen atoms of each C₆ arylene group can be disposed ortho, meta, or para (specifically para) to each other on the C₆ arylene group. Exemplary X^(a) groups include, but are not limited to, methylene, ethylidene, neopentylidene, isopropylidene, cyclohexylmethylidene, 1,1-ethene, 2-[2.2.1]-bicycloheptylidene, cyclohexylidene, cyclopentylidene, cyclododecylidene, and adamantylidene.

In certain embodiments, p and q are each 1; R^(a) and R^(b) are each a C₁-C₃ alkyl group, specifically methyl, disposed meta to the oxygen on each ring; and X^(a) is isopropylidene. In certain embodiments, p and q are both 0; and X^(a) is isopropylidene.

In certain embodiments, X^(a) can have formula (6):

wherein R^(c) and R^(d) are each independently hydrogen, halogen, alkyl (e.g., C₁-C₁₂ alkyl), cycloalkyl (e.g., C₃-C₁₂ cycloalkyl), cycloalkylalkyl (e.g., C₃-C₁-cycloalkyl-C₁-C₆-alkyl), aryl (e.g., C₆-C₁₂ aryl), arylalkyl (e.g., C₆-C₁₂-aryl-C₁-C₆-alkyl), heterocyclyl (e.g., five- or six-membered heterocyclyl having one, two, three, or four heteroatoms independently selected from nitrogen, oxygen, and sulfur), heterocyclylalkyl (e.g., five- or six-membered heterocyclyl-C₁-C₆-alkyl), heteroaryl (e.g., five- or six-membered heteroaryl having one, two, three, or four heteroatoms independently selected from nitrogen, oxygen, and sulfur), or heteroarylalkyl (e.g., five- or six-membered heteroaryl-C₁-C₆-alkyl), wherein said alkyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, and heteroarylalkyl are each independently unsubstituted or substituted (e.g., substituted with 1 to 3 substituents independently selected from the group consisting of —OH, —NH₂, —NO₂, —CN, halo, C₁-C₄-alkyl, C₁-C₄-alkoxy-C₁-C₄-alkyl, halo-C₁-C₄-alkyl, halo-C₁-C₄-alkoxy-C₁-C₄-alkyl, hydroxy-C₁-C₄-alkyl, amino-C₁-C₄-alkyl, C₁-C₄-alkylamino-C₁-C₄-alkyl, di(C₁-C₄-alkyl)amino-C₁-C₄-alkyl, azido-C₁-C₄-alkyl, cyano-C₁-C₄-alkyl, C₁-C₄-alkoxy, halo-C₁-C₄-alkoxy, C₁-C₄-alkoxy-C₁-C₄-alkoxy, C₂-C₄-alkenyl, and C₂-C₄-alkynyl). In certain embodiments, R^(c) and R^(d) are each independently hydrogen or C₁-C₈ alkyl. In certain embodiments, R^(c) and R^(d) are each methyl. Exemplary groups of formula (6) include, but are not limited to, methylene, ethylidene, neopentylidene, and isopropylidene.

In certain embodiments, X^(a) can have formula (7):

wherein R^(e) is a divalent C₁-C₃₁ group. In certain embodiments, R^(e) is a divalent hydrocarbyl (e.g., a C₁₂-C₃₁ hydrocarbyl), a cycloalkylidene (e.g., a C₅-C₁₈ cycloalkylidene), a cycloalkylene (e.g., a C₅-C₁₈ cycloalkylene), a heterocycloalkylidene (e.g., a C₃-C₁₈ heterocycloalkylidene), or a group of the formula —B¹-G-B²— wherein B¹ and B² are the same or different alkylene group (e.g., a C₁-C₆ alkylene group) and G is a cycloalkylidene group (e.g., a C₃-C₁₂ cycloalkylidene group) or an arylene group (e.g., a C₆-C₁₆ arylene group), wherein said hydrocarbyl, cycloalkylidene, cycloalkylene, and heterocycloalkylidene are each independently unsubstituted or substituted (e.g., substituted with 1 to 3 substituents independently selected from the group consisting of —OH, —NH₂, —NO₂, —CN, halo, C₁-C₄-alkyl, C₁-C₄-alkoxy-C₁-C₄-alkyl, halo-C₁-C₄-alkyl, halo-C₁-C₄-alkoxy-C₁-C₄-alkyl, hydroxy-C₁-C₄-alkyl, amino-C₁-C₄-alkyl, C₁-C₄-alkylamino-C₁-C₄-alkyl, di(C₁-C₄-alkyl)amino-C₁-C₄-alkyl, azido-C₁-C₄-alkyl, cyano-C₁-C₄-alkyl, C₁-C₄-alkoxy, halo-C₁-C₄-alkoxy, C₁-C₄-alkoxy-C₁-C₄-alkoxy, C₂-C₄-alkenyl, and C₂-C₄-alkynyl). Exemplary groups of formula (7) include, but are not limited to, 2-[2.2.1]-bicycloheptylidene, cyclohexylidene, cyclopentylidene, cyclododecylidene, and adamantylidene.

The repeating structural units of formula (5) can be derived from a dihydroxy monomer unit of formula (8):

wherein X^(a), R^(a), R^(b), p, and q are as defined above. In certain embodiments, p and q are both 0, and X^(a) is isopropylidene.

The polycarbonate can include repeating units of formula (9), formula (10), formula (11), or a combination thereof:

wherein R¹³ at each occurrence is independently a halogen or a C₁-C₆ alkyl group; R¹⁴ is independently a C₁-C₆ alkyl, phenyl, or phenyl substituted with up to five halogens or C₁-C₆ alkyl groups; R^(a) and R^(b), at each occurrence, are each independently a halogen, C₁-C₁₂ alkyl, C₁-C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; c is independently 0 to 4; and p and q are each independently 0 to 4. In a specific embodiment, R¹⁴ is a C₁-C₆ alkyl or phenyl group. In still another embodiment, R¹⁴ is a methyl or phenyl group. In another specific embodiment, c is 0; p is 0; and q is 0.

The repeating structural units of formula (9) can be derived from a dihydroxy monomer unit of formula (12); the repeating structural units of formula (10) can be derived from a dihydroxy monomer unit of formula (13); and the repeating structural units of formula (11) can be derived from a dihydroxy monomer unit of formula (14):

wherein R^(a), R^(b), R¹³, c, p, and q are as defined above. Such dihydroxy compounds can be useful for high heat applications.

The dihydroxy compound of formula (12) can have formula (15), which can be useful for high heat applications:

(also known as 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one (PPPBP)).

The polycarbonate can include repeating units of formula (16):

wherein R^(a) and R^(b) are each independently halogen, C₁-C₁₂ alkyl, C₁-C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; R^(g) is independently C₁-C₁₂ alkyl or halogen, or two R^(g) groups together with the carbon atoms to which they are attached can form a four-, five, or six-membered cycloalkyl group; p and q are each independently 0 to 4; and t is 0 to 10. R^(a) and R^(b) can be disposed meta to the cyclohexylidene bridging group. The substituents R^(a), R^(b) and R^(g) can, when comprising an appropriate number of carbon atoms, be straight chain, cyclic, bicyclic, branched, saturated, or unsaturated. In one example, R^(a), R^(b) and R^(g) are each independently C₁-C₄ alkyl, p and q are each 0 or 1, and t is 0 to 5. In another example, R^(a), R^(b) and R^(g) are each methyl, p and q are each 0 or 1, and t is 0 or 3. The cyclohexylidene-bridged bisphenol can be the reaction product of two moles of o-cresol with one mole of cyclohexanone. In another example, the cyclohexylidene-bridged bisphenol can be the reaction product of two moles of a cresol with one mole of a hydrogenated isophorone (e.g., 1,1,3-trimethyl-3-cyclohexane-5-one). Such cyclohexane-containing bisphenols, for example the reaction product of two moles of a phenol with one mole of a hydrogenated isophorone, are useful for making polycarbonate polymers with high Tgs and high heat distortion temperatures. Cyclohexyl bisphenol-containing polycarbonates, or a combination comprising at least one of the foregoing with other bisphenol polycarbonates, are supplied by Bayer Co. under the APEC trade name.

The repeating structural units of formula (16) can be derived from a dihydroxy monomer unit of formula (17):

wherein R^(a), R^(b), R^(g), p, q, and t are as defined above.

The dihydroxy compound of formula (17) can have formula (18) (also known as 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (DMBPC)), or of formula (19) (also known as bisphenol isophorone), or of formula (20), any of which can be useful for high heat applications:

The polycarbonate can include repeating units of formula (21):

wherein R^(r), R^(p), R^(q) and R^(t) are each independently hydrogen, halogen, oxygen, or a C₁-C₁₂ organic group; R^(a) and R^(b) are each independently halogen, C₁-C₁₂ alkyl, C₁-C₁₂ alkenyl, (C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; I is a direct bond, a carbon, or a divalent oxygen, sulfur, or —N(Z)— where Z is hydrogen, halogen, hydroxy, C₁-C₁₂ alkyl, C₁-C₁₂ alkoxy, C₆-C₁₂ aryl, or C₁-C₁₂ acyl; h is 0 to 2, j is 1 or 2, i is an integer of 0 or 1, k is an integer of 0 to 3, p is an integer of 0 to 4, and q is an integer 0 to 4, with the proviso that at least two of R^(r), R^(p), R^(q) and R^(t) taken together are a fused cycloaliphatic, aromatic, or heteroaromatic ring. It will be understood that where the fused ring is aromatic, the ring as shown in formula (21) will have an unsaturated carbon-carbon linkage where the ring is fused. When i is 0, h is 0, and k is 1, the ring as shown in formula (21) contains 4 carbon atoms; when i is 0, h is 0, and k is 2, the ring as shown contains 5 carbon atoms, and when i is 0, h is 0, and k is 3, the ring contains 6 carbon atoms. In one example, two adjacent groups (e.g., R^(q) and R^(t) taken together) form an aromatic group, and in another embodiment, R^(q) and R^(t) taken together form one aromatic group and R^(r) and R^(p) taken together form a second aromatic group. When R^(q) and R^(t) taken together form an aromatic group, R^(p) can be a double-bonded oxygen atom, i.e., a ketone.

The repeating structural units of formula (21) can be derived from a dihydroxy monomer unit of formula (22):

wherein R^(a), R^(b), R^(r), R^(p), R^(q), R^(t), I, h, i, j, k, p, and q are as defined above.

The polycarbonate can include repeating units of formula (23):

wherein R^(a) and R^(b) are each independently halogen, C₁-C₁₂ alkyl, C₁-C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; and p and q are each independently 0 to 4. In certain embodiments, at least one of each of R^(a) and R^(b) are disposed meta to the cycloalkylidene bridging group. In certain embodiments, R^(a) and R^(b) are each independently C₁-C₃ alkyl; and p and q are each 0 or 1. In certain embodiments, R^(a) and R^(b) are each methyl; and p and q are each 0 or 1.

The repeating structural units of formula (23) can be derived from a dihydroxy monomer unit of formula (24):

wherein R^(a), R^(b), p, and q are as defined above. Such dihydroxy compounds that might impart high Tgs to the polycarbonate as a copolycarbonate are described in U.S. Pat. No. 7,244,804.

The dihydroxy compound of formula (24) can have formula (25), which can be useful for high heat applications:

(also known as 9,9-bis(4-hydroxyphenyl)fluorene).

The polycarbonate can include repeating units of formula (26):

wherein R^(a) and R^(b) are each independently halogen, C₁-C₁₂ alkyl, C₁-C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; and p and q are each independently 0 to 4. In certain embodiments, at least one of each of R^(a) and R^(b) are disposed meta to the cycloalkylidene bridging group. In certain embodiments, R^(a) and R^(b) are each independently C₁-C₃ alkyl; and p and q are each 0 or 1. In certain embodiments, R^(a) and R^(b) are each methyl; and p and q are each 0 or 1.

The repeating structural units of formula (26) can be derived from a dihydroxy monomer unit of formula (27):

wherein R^(a), R^(b), p, and q are as defined above. Such dihydroxy compounds that might impart high Tgs to the polycarbonate are described in U.S. Pat. Nos. 7,112,644 and 3,516,968.

The dihydroxy compound of formula (27) can have formula (28), which can be useful for high heat applications:

(also known as 2,2-bis(4-hydroxyphenyl)adamantane).

A dihydroxy compound of formula (29) can be useful for high heat applications:

(also known as 4,4′-(1-phenylethane-1,1-diyl)diphenol (bisphenol-AP) or 1,1-bis(4-hydroxyphenyl)-1-phenyl-ethane).

A dihydroxy compound of formula (30) can be useful for high heat applications:

(also known as 6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane).

A dihydroxy compound of formula (31) can be useful for high heat applications:

(also known as 4,4′-(3,3-dimethyl-2,2-dihydro-1H-indene-1,1-diyl)diphenol).

Exemplary monomers for inclusion in the polycarbonate include, but are not limited to, 4,4′-dihydroxybiphenyl, 1,1-bis(4-hydroxyphenyl)methane, bis(4-hydroxyphenyl)acetonitrile, bis(4-hydroxyphenyl)phenylmethane, bis(4-hydroxyphenyl)-1-naphthylmethane, 1,1-bis(4-hydroxyphenyl)ethane, 1,2-bis(4-hydroxyphenyl)ethane, 1,1-bis(4-hydroxyphenyl)-1-phenylethane, 1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene, 1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene, 1,1-bis(4-hydroxyphenyl)propane, 1,1-bis(4-hydroxy-t-butylphenyl)propane, 2,2-bis(4-hydroxyphenyl)propane (“bisphenol-A” or “BPA”), 2-(4-hydroxyphenyl)-2-(3-hydroxyphenyl)propane, 2,2-bis(4-hydroxy-2-methylphenyl)propane, 2,2-bis(3-methyl-4-hydroxyphenyl)propane, 2,2-bis(3-ethyl-4-hydroxyphenyl)propane, 2,2-bis(3-n-propyl-4-hydroxyphenyl)propane, 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane, 2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane, 2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane, 2,2-bis(3-allyl-4-hydroxyphenyl)propane, 2,2-bis(3-methoxy-4-hydroxyphenyl)propane, 2,2-bis(4-hydroxy-3-bromophenyl)propane, 2,2-bis(4-hydroxyphenyl)hexafluoropropane, 1,1-bis(4-hydroxyphenyl)n-butane, 2,2-bis(4-hydroxyphenyl)butane, 3,3-bis(4-hydroxyphenyl)-2-butanone, 1,1-bis(4-hydroxyphenyl)isobutene, trans-2,3-bis(4-hydroxyphenyl)-2-butene, 1,6-bis(4-hydroxyphenyl)-1,6-hexanedione, 2,2-bis(4-hydroxyphenyl)octane, 1,1-bis(hydroxyphenyl)cyclopentane, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)cyclododecane, 2,2-bis(4-hydroxyphenyl)adamantane, (alpha, alpha′-bis(4-hydroxyphenyl)toluene, 4,4′-dihydroxybenzophenone, 2,7-dihydroxypyrene, bis(4-hydroxyphenyl)ether, ethylene glycol bis(4-hydroxyphenyl)ether, bis(4-hydroxyphenyl)sulfide, bis(4-hydroxyphenyl)sulfoxide, bis(4-hydroxyphenyl)sulfone, bis(4-hydroxyphenyl)diphenylmethane, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, 6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane (“spirobiindane bisphenol”), 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, 2,7-dihydroxycarbazole, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (also referred to as 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one or “PPPBP”), 9,9-bis(4-hydroxyphenyl)fluorene, and bisphenol isophorone (also referred to as 4,4′-(3,3,5-trimethylcyclohexane-1,1-diyl)diphenol or “BPI”), 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (“DMBPC”), tricyclopentadienyl bisphenol (also referred to as 4,4′-(octahydro-1H-4,7-methanoindene-5,5-diyl)diphenol), 2,2-bis(4-hydroxyphenyl)adamantane (“BCF”), 1,1-bis(4-hydroxyphenyl)-1-phenyl ethane (“BPAP”), and 3,3-bis(4-hydroxyphenyl)phthalide, or any combination thereof.

Exemplary monomers useful for increasing the Tg of the polycarbonate include, but are not limited to, bis(4-hydroxyphenyl)diphenylmethane, 1,6-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, 6,6′-dihydroxy-3,3,3′,3′-tetramethylspiro(bis)indane (“spirobiindane bisphenol”), 2,6-dihydroxydibenzo-p-dioxin, 2,6-dihydroxythianthrene, 2,7-dihydroxyphenoxathin, 2,7-dihydroxy-9,10-dimethylphenazine, 3,6-dihydroxydibenzofuran, 3,6-dihydroxydibenzothiophene, 2,7-dihydroxycarbazole, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (also referred to as 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one or “PPPBP”), 9,9-bis(4-hydroxyphenyl)fluorene, and bisphenol isophorone (also referred to as 4,4′-(3,3,5-trimethylcyclohexane-1,1-diyl)diphenol or “BPI”), 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane (“DMBPC”), tricyclopentadienyl bisphenol (also referred to as 4,4′-(octahydro-1H-4,7-methanoindene-5,5-diyl)diphenol), 2,2-bis(4-hydroxyphenyl)adamantane (“BCF”), 1,1-bis(4-hydroxyphenyl)-1-phenyl ethane (“BPAP”), and 3,3-bis(4-hydroxyphenyl)phthalide, or any combination thereof.

Other dihydroxy monomer units that can be used include aromatic dihydroxy compounds of formula (32):

wherein each R^(h) is independently a halogen atom, a C₁-C₁₀ hydrocarbyl such as a C₁-C₁₀ alkyl group, or a halogen substituted C₁-C₁₀ hydrocarbyl such as a halogen-substituted C₁-C₁₀ alkyl group, and n is 0 to 4. The halogen, when present, is usually bromine.

Examples of aromatic dihydroxy compounds represented by formula (31) include, but are not limited to, resorcinol, substituted resorcinol compounds (e.g., 5-methyl resorcinol, 5-ethyl resorcinol, 5-propyl resorcinol, 5-butyl resorcinol, 5-t-butyl resorcinol, 5-phenyl resorcinol, 5-cumyl resorcinol, 2,4,5,6-tetrafluoro resorcinol, 2,4,5,6-tetrabromo resorcinol), catechol, hydroquinone, substituted hydroquinones (e.g., 2-methyl hydroquinone, 2-ethyl hydroquinone, 2-propyl hydroquinone, 2-butyl hydroquinone, 2-t-butyl hydroquinone, 2-phenyl hydroquinone, 2-cumyl hydroquinone, 2,3,5,6-tetramethyl hydroquinone, 2,3,5,6-tetra-t-butyl hydroquinone, 2,3,5,6-tetrafluoro hydroquinone, 2,3,5,6-tetrabromo hydroquinone, and the like, as well as combinations thereof.

The compositions can include one or more polyester-polycarbonate copolymers. The polyester-polycarbonate can comprise repeating ester units of formula (33):

wherein O-D-O of formula (33) is a divalent group derived from a dihydroxy compound, and D can be, for example, one or more alkyl containing C₆-C₂₀ aromatic group(s), or one or more C₆-C₂₀ aromatic group(s), a C₂-C₁₀ alkylene group, a C₆-C₂₀ alicyclic group, a C₆-C₂₀ aromatic group or a polyoxyalkylene group in which the alkylene groups contain 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms, 1) can be a C₂-C₃₀ alkylene group having a straight chain, branched chain, or cyclic (including polycyclic) structure. O-D-O can be derived from a compound of formula (2), as described above. O-D-O can be derived from an aromatic dihydroxy compound of formula (4), as described above. O-D-O can be derived from an aromatic dihydroxy compound of formula (8), as described above.

The molar ratio of ester units to carbonate units in the polyester-polycarbonates can vary broadly, for example 1:99 to 99:1, specifically 10:90 to 90:10, more specifically 25:75 to 75:25, optionally expanded depending on the desired properties of the final composition.

T of formula (33) can be a divalent group derived from a dicarboxylic acid, and can be, for example, a C₂-C₁₀ alkylene group, a C₆-C₂₀ alicyclic group, a C₆-C₂₀ alkyl aromatic group, a C₆-C₂₀ aromatic group, or a C₆-C₃₆ divalent organic group derived from a dihydroxy compound or chemical equivalent thereof. T can be an aliphatic group, wherein the molar ratio of carbonate units to ester units of formula (33) in the poly(aliphatic ester)-polycarbonate copolymer is from 99:1 to 60:40; and 0.01 to 10 weight percent, based on the total weight of the polymer component, of a polymeric containing compound. T can be derived from a C₆-C₂₀ linear aliphatic alpha-omega (α-ω) dicarboxylic ester.

Diacids from which the T group in the ester unit of formula (33) is derived include aliphatic dicarboxylic acids having from 6 to 36 carbon atoms, optionally from 6 to 20 carbon atoms. The C₆-C₂₀ linear aliphatic alpha-omega (α-ω) dicarboxylic acids can be adipic acid, sebacic acid, 3,3-dimethyl adipic acid, 3,3,6-trimethyl sebacic acid, 3,3,5,5-tetramethyl sebacic acid, azelaic acid, dodecanedioic acid, dimer acids, cyclohexane dicarboxylic acids, dimethyl cyclohexane dicarboxylic acid, norbornane dicarboxylic acids, adamantane dicarboxylic acids, cyclohexene dicarboxylic acids, or C₁₄, C₁₈ and C₂₀ diacids.

The ester units of the polyester-polycarbonates of formula (33) can be further described by formula (34), wherein T is (CH₂)_(m), where m is 4 to 40 or optionally m is 4 to 18. m can be 8 to 10.

Saturated aliphatic alpha-omega dicarboxylic acids can be adipic acid, sebacic or dodecanedioic acid. Sebacic acid is a dicarboxylic acid having the following formula (35):

Sebacic acid has a molecular mass of 202.25 Da, a density of 1.209 g/cm³ (at 25° C.), and a melting point of 294.4° C. at 100 mmHg. Sebacic acid is extracted from castor bean oil found in naturally occurring castor beans.

The poly(aliphatic ester)-polycarbonate can include less than or equal to 25 mol % of the aliphatic dicarboxylic acid unit. The poly(aliphatic ester)-polycarbonate can comprise units of formula (34) in an amount of 0.5 to 10 mol %, specifically 1 to 9 mol %, and more specifically 3 to 8 mol %, based on the total amount of the poly(aliphatic ester)-polycarbonate.

The poly(aliphatic ester)-polycarbonate can be a copolymer of aliphatic dicarboxylic acid units and carbonate units. The poly(aliphatic ester)-polycarbonate is shown in formula (36):

where each R³ is independently derived from a dihydroxyaromatic compound of formula (8) or (32), m is 4 to 18, and x and y each represent average weight percentages of the poly(aliphatic ester)-polycarbonate where x+y is 100.

A specific embodiment of the poly(aliphatic ester)-polycarbonate is shown in formula (37), where m is 4 to 18 and x and y are as defined for formula (36)

In some embodiments, a useful poly(aliphatic ester)-polycarbonate copolymer comprises sebacic acid ester units and bisphenol A carbonate units (formula (37), where m is 8).

Desirably, the poly(aliphatic ester)-polycarbonate has a Tg of 100 to 145° C.

Other examples of aromatic dicarboxylic acids that can be used to prepare the polyester units include isophthalic, terephthalic acid, 1,2-di(p-carboxyphenyl)ethane, 4,4′-dicarboxydiphenyl ether, 4,4′-bisbenzoic acid, and combinations comprising at least one of the foregoing acids. Acids containing fused rings can also be present, such as in 1,4-, 1,5-, or 2,6-naphthalenedicarboxylic acids. Specific dicarboxylic acids can be terephthalic acid, isophthalic acid, naphthalene dicarboxylic acid, cyclohexane dicarboxylic acid, or combinations thereof. A specific dicarboxylic acid comprises a combination of isophthalic acid and terephthalic acid wherein the weight ratio of isophthalic acid to terephthalic acid is 91:9 to 2:98.

D of the repeating units of formula (33) can also be a C₂-C₆ alkylene group and T can be p-phenylene, m-phenylene, naphthalene, a divalent cycloaliphatic group, or a combination thereof. This class of polyester includes the poly(alkylene terephthalates).

Mixtures of the diacids can also be employed. It should be noted that although referred to as diacids, any ester precursor could be employed such as acid halides, specifically acid chlorides, and diaromatic esters of the diacid such as diphenyl, for example the diphenyl ester of sebacic acid. With reference to the diacid carbon atom number earlier mentioned, this does not include any carbon atoms which can be included in the ester precursor portion, for example diphenyl. It can be desirable that at least four, five or six carbon bonds separate the acid groups. This can reduce the formation of undesirable and unwanted cyclic species.

The polyester unit of a polyester-polycarbonate can be derived from the reaction of a combination of isophthalic and terephthalic diacids (or derivatives thereof) with resorcinol. In another embodiment, the polyester unit of a polyester-polycarbonate can be derived from the reaction of a combination of isophthalic acid and terephthalic acid with BPA. In some embodiments, the polycarbonate units can be derived from BPA. In another specific embodiment, the polycarbonate units can be derived from resorcinol and BPA in a molar ratio of resorcinol carbonate units to BPA carbonate units of 1:99 to 99:1.

In certain embodiments, the polyester-polycarbonate is a copolymer of formula (38):

wherein the polyester-polycarbonate includes bisphenol A carbonate blocks, and polyester blocks made of a copolymer of bisphenol A with isophthalate, terephthalate or a combination of isophthalate and terephthalate. Further in the polyester-polycarbonate (38), x and y represent the respective parts by weight of the aromatic carbonate units and the aromatic ester units based on 100 parts total weight of the copolymer. Specifically, x, the carbonate content, is from more than zero to 80 wt %, from 5 to 70 wt %, still more specifically from 5 to 50 wt %, and y, the aromatic ester content, is 20 to less than 100 wt %, specifically 30 to 95 wt %, still more specifically 50 to 95 wt %, each based on the total weight of units x+y. The weight ratio of terephthalic acid to isophthalic acid can be in the range of from 5:95 to 95:5. Polyester-polycarbonate (38) comprising 35 to 45 wt % of carbonate units and 55 to 65 wt % of ester units, wherein the ester units have a molar ratio of isophthalate to terephthalate of 45:55 to 55:45 can be referred to as PCE; and copolymers comprising 15 to 25 wt % of carbonate units and 75 to 85 wt % of ester units having a molar ratio of isophthalate to terephthalate from 98:2 to 88:12 can be referred to as PPC. In these embodiments the PCE or PPC can be derived from reaction of bisphenol-A and phosgene with iso- and terephthaloyl chloride, and can have an intrinsic viscosity of 0.5 to 0.65 deciliters per gram (measured in methylene chloride at a temperature of 25° C.).

Useful polyesters can include aromatic polyesters, poly(alkylene esters) including poly(alkylene arylates), and poly(cycloalkylene diesters). Aromatic polyesters can have a polyester structure according to formula (33), wherein D and T are each aromatic groups as described hereinabove. Useful aromatic polyesters can include, for example, poly(isophthalate-terephthalate-resorcinol) esters, poly(isophthalate-terephthalate-bisphenol-A) esters, poly[(isophthalate-terephthalate-resorcinol) ester-co-(isophthalate-terephthalate-bisphenol-A)] ester, or a combination comprising at least one of these.

End capping agents can be incorporated into the polycarbonates. Exemplary chain-stoppers include certain monophenolic compounds (i.e., phenyl compounds having a single free hydroxy group), monocarboxylic acid chlorides, monocarboxylic acids, and monochloroformates. Phenolic chain-stoppers are exemplified by phenol and C₁-C₂₂ alkyl-substituted phenols such as p-cumyl-phenol (PCP), resorcinol monobenzoate, and p-tertiary-butylphenol, cresol, and monoethers of diphenols, such as p-methoxyphenol. Exemplary chain-stoppers also include cyanophenols, such as for example, 4-cyanophenol, 3-cyanophenol, 2-cyanophenol, and polycyanophenols. Alkyl-substituted phenols with branched chain alkyl substituents having 8 to 9 carbon atoms can be specifically be used.

Endgroups can be derived from the carbonyl source (i.e., the diaryl carbonate), from selection of monomer ratios, incomplete polymerization, chain scission, and the like, as well as any added endcapping groups, and can include derivatizable functional groups such as hydroxy groups, carboxylic acid groups, or the like. In some embodiments, the endgroup of a polycarbonate can comprise a structural unit derived from a diaryl carbonate, where the structural unit can be an endgroup. In a further embodiment, the endgroup is derived from an activated carbonate. Such endgroups can derive from the transesterification reaction of the alkyl ester of an appropriately substituted activated carbonate, with a hydroxy group at the end of a polycarbonate polymer chain, under conditions in which the hydroxy group reacts with the ester carbonyl from the activated carbonate, instead of with the carbonate carbonyl of the activated carbonate. In this way, structural units derived from ester containing compounds or substructures derived from the activated carbonate and present in the melt polymerization reaction can form ester endgroups. In some embodiments, the ester endgroup derived from a salicylic ester can be a residue of bis(methyl salicyl) carbonate (BMSC) or other substituted or unsubstituted bis(alkyl salicyl) carbonate such as bis(ethyl salicyl) carbonate, bis(propyl salicyl) carbonate, bis(phenyl salicyl) carbonate, bis(benzyl salicyl) carbonate, or the like. In a specific embodiment, where BMSC is used as the activated carbonyl source, the endgroup is derived from and is a residue of BMSC, and is an ester endgroup derived from a salicylic acid ester as is known in the art.

The polycarbonates can be manufactured by processes such as interfacial polymerization, melt polymerization, and reactive extrusion. High Tg copolycarbonates are generally manufactured using interfacial polymerization.

Polycarbonates produced by interfacial polymerization can have an aryl hydroxy end-group content of 150 parts per million (ppm) or less, 100 ppm or less, or 50 ppm or less. Polycarbonates produced by melt polymerization can have an aryl hydroxy end-group content of greater than or equal to 350 ppm, greater than or equal to 400 ppm, greater than or equal to 450 ppm, greater than or equal to 500 ppm, greater than or equal to 550 ppm, greater than or equal to 600 ppm, greater than or equal to 650 ppm, greater than or equal to 700 ppm, greater than or equal to 750 ppm, greater than or equal to 800 ppm, or greater than or equal to 850 ppm.

Reaction conditions for interfacial polymerization can vary. An exemplary process generally involves dissolving or dispersing one or more dihydric phenol reactants, such as BPA, in aqueous caustic soda or potash, adding the resulting mixture to a water-immiscible solvent medium (e.g., methylene chloride), and contacting the reactants with a carbonate precursor (e.g., phosgene) in the presence of a catalyst such as, for example, a tertiary amine (e.g., triethylamine) or a phase transfer catalyst, under controlled pH conditions, e.g., 8 to 11. The most commonly used water immiscible solvents include methylene chloride, 1,2-dichloroethane, chlorobenzene, toluene, and the like.

Exemplary carbonate precursors can include, for example, a carbonyl halide such as carbonyl dibromide or carbonyl dichloride (also known as phosgene), or a haloformate such as a bishaloformate of a dihydric phenol (e.g., the bischloroformate of BPA, hydroquinone, or the like) or a glycol (e.g., the bishaloformate of ethylene glycol, neopentyl glycol, polyethylene glycol, or the like). Combinations comprising at least one of the foregoing types of carbonate precursors can also be used. In certain embodiments, the carbonate precursor is phosgene, a triphosgene, diacyl halide, dihaloformate, dicyanate, diester, diepoxy, diarylcarbonate, dianhydride, dicarboxylic acid, diacid chloride, or any combination thereof. An interfacial polymerization reaction to form carbonate linkages can use phosgene as a carbonate precursor, and is referred to as a phosgenation reaction.

Among tertiary amines that can be used are aliphatic tertiary amines such as triethylamine, tributylamine, cycloaliphatic amines such as N,N-diethyl-cyclohexylamine and aromatic tertiary amines such as N,N-dimethylaniline.

Among the phase transfer catalysts that can be used are catalysts of the formula (R³⁰)₄Q⁺X, wherein each R³⁰ is the same or different, and is a C₁-C₁₀ alkyl group; Q is a nitrogen or phosphorus atom; and X is a halogen atom, C₁-C₈ alkoxy group, or C₆-C₁₈ aryloxy group. Exemplary phase transfer catalysts include, for example, [CH₃(CH₂)₃]₄NX, [CH₃(CH₂)₃]₄PX, [CH₃(CH₂)₅]₄NX, [CH₃(CH₂)₆]₄NX, [CH₃(CH₂)₄]₄NX, CH₃[CH₃(CH₂)₃]₃NX, and CH₃[CH₃(CH₂)₂]₃NX, wherein X is Cl⁻, Br⁻, a C₁-C₈ alkoxy group or a C₆-C₁₈ aryloxy group. An effective amount of a phase transfer catalyst can be 0.1 to 10 wt % based on the weight of bisphenol in the phosgenation mixture. For example, an effective amount of phase transfer catalyst can be 0.5 to 2 wt % based on the weight of bisphenol in the phosgenation mixture.

Specifically, polyester-polycarbonates, including the poly(aliphatic ester)-polycarbonates, can be prepared by interfacial polymerization. Rather than utilizing the dicarboxylic acid (such as the alpha, omega C₆₋₂₀ aliphatic dicarboxylic acid) per se, it is possible, and sometimes even preferred, to employ the reactive derivatives of the dicarboxylic acid, such as the corresponding dicarboxylic acid halides, and in particular the acid dichlorides and the acid dibromides. Thus, for example instead of using isophthalic acid, terephthalic acid, or a combination comprising at least one of the foregoing (for poly(arylate ester)-polycarbonates), it is possible to employ isophthaloyl dichloride, terephthaloyl dichloride, and a combination comprising at least one of the foregoing. Similarly, for the poly(aliphatic ester)-polycarbonates, it is possible, and even desirable, to use for example acid chloride derivatives such as a C₆ dicarboxylic acid chloride (adipoyl chloride), a C₁₀ dicarboxylic acid chloride (sebacoyl chloride), or a C₁₂ dicarboxylic acid chloride (dodecanedioyl chloride). The dicarboxylic acid or reactive derivative can be condensed with the dihydroxyaromatic compound in a first condensation, followed by in situ phosgenation to generate the carbonate linkages with the dihydroxyaromatic compound. Alternatively, the dicarboxylic acid or derivative can be condensed with the dihydroxyaromatic compound simultaneously with phosgenation.

The polymers can be manufactured using a reactive extrusion process. For example, a poly(aliphatic ester)-polycarbonate can be modified to provide a reaction product with a higher flow by treatment using a redistribution catalyst under conditions of reactive extrusion. For example, a poly(aliphatic ester)-polycarbonate with an melt volume flow rate (MVR) of less than 13 cc/10 min when measured at 250° C., under a load of 1.2 kg, can be modified to provide a reaction product with a higher flow (e.g., greater than or equal to 13 cc/10 min when measured at 250° C., under a load of 1.2 kg), by treatment using a redistribution catalyst under conditions of reactive extrusion. During reactive extrusion, the redistribution catalyst can be injected into the extruder being fed with the poly(aliphatic ester)-polycarbonate, and optionally one or more additional components.

The redistribution catalyst can be included in the extrusion process in small amounts of less than or equal to 400 ppm by weight, for example. The redistribution catalyst can be present in amounts of from 0.01 to 0.05 parts per hundred (pph), from 0.1 to 0.04 pph, from 0.02 to 0.03 pph, from 0.1 to 1 pph, from 1 to 500 pph, from 100 to 400 pph, from 300 to 400 pph, from 100 to 400 ppm, from 200 to 300 ppm, or from 1 to 300 ppm by weight based on the weight of the poly(aliphatic ester)-polycarbonate. The redistribution catalyst can be present in an amount of 40 to 120 ppm, specifically 40 to 110 ppm, and more specifically 40 to 100 ppm, by weight based on the weight of the poly(aliphatic ester)-polycarbonate.

The redistribution catalyst can be injected into the extruder as a diluted aqueous solution. For example, the redistribution catalyst can be a 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 99% solution. The redistribution catalyst can be diluted in water.

Examples of redistribution catalysts include a tetraalkylphosphonium hydroxide, a tetraalkylphosphonium alkoxide, a tetraalkylphosphonium aryloxide, a tetraalkylphosphonium carbonate, a tetraalkylammonium hydroxide, a tetraalkylammonium carbonate, a tetraalkylammonium phosphite, a tetraalkylammonium acetate, or a combination comprising at least one of the foregoing catalysts, wherein each alkyl is independently a C₁₋₆ alkyl. Particularly useful redistribution catalysts include a tetra C₁₋₆ alkylphosphonium hydroxide, a C₁₋₆ alkyl phosphonium phenoxide, or a combination comprising one or more of the foregoing catalysts. An exemplary redistribution catalyst is tetra-n-butylphosphonium hydroxide. In certain embodiments, the redistribution catalyst can not react with epoxy.

The polycarbonates can be prepared by a melt polymerization process. Generally, in the melt polymerization process, polycarbonates are prepared by co-reacting, in a molten state, the dihydroxy reactant(s) (e.g., bisphenols, aromatic dihydroxy compounds, aliphatic diols, aliphatic diacids, and any additional dihydroxy compound) and a diaryl carbonate ester, such as diphenyl carbonate, or more specifically in some embodiments, an activated carbonate such as bis(methyl salicyl) carbonate, in the presence of a transesterification catalyst. The reaction can be carried out in typical polymerization equipment, such as one or more continuously stirred tank reactors (CSTR's), plug flow reactors, wire wetting fall polymerizers, free fall polymerizers, wiped film polymerizers, BANBURY® mixers, single or twin screw extruders, or combinations of the foregoing. Volatile monohydric phenol is removed from the molten reactants by distillation and the polymer is isolated as a molten residue.

A specifically useful melt process for making polycarbonates uses a diaryl carbonate ester having electron-withdrawing substituents on the aryls, which can be referred to herein as an “activated carbonate.” Examples of specifically useful diaryl carbonate esters with electron withdrawing substituents include bis(4-nitrophenyl)carbonate, bis(2-chlorophenyl)carbonate, bis(4-chlorophenyl)carbonate, bis(methyl salicyl)carbonate, bis(4-methylcarboxylphenyl)carbonate, bis(2-acetylphenyl)carboxylate, bis(4-acetylphenyl)carboxylate, or a combination comprising at least one of the foregoing. Bis(methyl salicyl)carbonate can be used as the activated carbonate in melt polycarbonate synthesis due to its lower molecular weight and higher vapor pressure.

The melt polymerization can include a transesterification catalyst comprising a first catalyst, also referred to herein as an alpha catalyst, comprising a metal cation and an anion. In an aspect, the cation is an alkali or alkaline earth metal comprising Li, Na, K, Cs, Rb, Mg, Ca, Ba, Sr, or a combination comprising at least one of the foregoing. The anion is hydroxide (OH⁻), superoxide (O₂ ⁻), thiolate (HS⁻), sulfide (S₂ ⁻), a C₁-C₂₀ alkoxide, a C₆-C₂₀ aryloxide, a C₁-C₂₀ carboxylate, a phosphate including biphosphate, a C₁-C₂₀ phosphonate, a sulfate including bisulfate, sulfites including bisulfates and metabisulfites, a C₁-C₂₀ sulfonate, a carbonate including bicarbonate, or a combination comprising at least one of the foregoing. In another aspect, salts of an organic acid comprising both alkaline earth metal ions and alkali metal ions can also be used. Salts of organic acids useful as catalysts are illustrated by alkali metal and alkaline earth metal salts of formic acid, acetic acid, stearic acid and ethyelenediamine tetraacetic acid. The catalyst can also comprise the salt of a non-volatile inorganic acid. By “nonvolatile”, it is meant that the referenced compounds have no appreciable vapor pressure at ambient temperature and pressure. In particular, these compounds are not volatile at temperatures at which melt polymerizations of polycarbonate are typically conducted. The salts of nonvolatile acids are alkali metal salts of phosphites; alkaline earth metal salts of phosphites; alkali metal salts of phosphates; and alkaline earth metal salts of phosphates. Exemplary transesterification catalysts include, lithium hydroxide, sodium hydroxide, potassium hydroxide, cesium hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, lithium formate, sodium formate, potassium formate, cesium formate, lithium acetate, sodium acetate, potassium acetate, lithium carbonate, sodium carbonate, potassium carbonate, lithium methoxide, sodium methoxide, potassium methoxide, lithium ethoxide, sodium ethoxide, potassium ethoxide, lithium phenoxide, sodium phenoxide, potassium phenoxide, sodium sulfate, potassium sulfate, NaH₂PO₃, NaH₂PO₄, Na₂PO₃, KH₂PO₄, CsH₂PO₄, Cs₂H₂PO₄, Na₂SO₃, Na₂S₂O₅, sodium mesylate, potassium mesylate, sodium tosylate, potassium tosylate, magnesium disodium ethylenediamine tetraacetate (EDTA magnesium disodium salt), or a combination comprising at least one of the foregoing. It will be understood that the foregoing list is exemplary and should not be considered as limited thereto. In some embodiments, the transesterification catalyst is an alpha catalyst consisting essentially of an alkali or alkaline earth salt. In an exemplary aspect, the transesterification catalyst consists essentially of sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium methoxide, potassium methoxide, NaH₂PO₄, or a combination comprising at least one of the foregoing.

The amount of alpha catalyst can vary widely according to the conditions of the melt polymerization, and can be 0.001 to 500 micromoles (μmol). In an aspect, the amount of alpha catalyst can be 0.01 to 20 μmol, specifically 0.1 to 10 μmol, more specifically 0.5 to 9 μmol, and still more specifically 1 to 7 μmol, per mole of aliphatic diol and any other dihydroxy compound present in the melt polymerization.

A second transesterification catalyst, also referred to herein as a beta catalyst, can optionally be included in the melt polymerization process, provided that the inclusion of such a second transesterification catalyst does not significantly adversely affect the desirable properties of the polymer. Exemplary transesterification catalysts can further include a combination of a phase transfer catalyst of formula (R³⁰)₄Q⁺X above, wherein each R³⁰ is the same or different, and is a C₁-C₁₀ alkyl group; Q is a nitrogen or phosphorus atom; and X is a halogen atom or a C₁-C₈ alkoxy group or C₆-C₁₈ aryloxy group. Exemplary phase transfer catalyst salts include, for example, [CH₃(CH₂)₃]₄NX, [CH₃(CH₂)₃]₄PX, [CH₃(CH₂)₅]₄NX, [CH₃(CH₂)₆]₄NX, [CH₃(CH₂)₄]₄NX, CH₃[CH₃(CH₂)₃]NX, and CH₃[CH₃(CH₂)₂]₃NX, wherein X is C⁻, Br⁻, a C₁-C₈ alkoxy group or a C₆-C₁₈ aryloxy group. Examples of such transesterification catalysts include tetrabutylammonium hydroxide, methyltributylammonium hydroxide, tetrabutylammonium acetate, tetrabutylphosphonium hydroxide, tetrabutylphosphonium acetate, tetrabutylphosphonium phenolate, or a combination comprising at least one of the foregoing. Other melt transesterification catalysts include alkaline earth metal salts or alkali metal salts. In various aspects, where a beta catalyst is desired, the beta catalyst can be present in a molar ratio, relative to the alpha catalyst, of less than or equal to 10, specifically less than or equal to 5, more specifically less than or equal to 1, and still more specifically less than or equal to 0.5. In other aspects, the melt polymerization reaction disclosed herein uses only an alpha catalyst as described hereinabove, and is substantially free of any beta catalyst. As defined herein, “substantially free of” can mean where the beta catalyst has been excluded from the melt polymerization reaction. In some embodiments, the beta catalyst is present in an amount of less than 10 ppm, specifically less than 1 ppm, more specifically less than 0.1 ppm, more specifically less than or equal to 0.01 ppm, and more specifically less than or equal to 0.001 ppm, based on the total weight of all components used in the melt polymerization reaction.

Where a combination of alpha and beta catalysts are used in the melt polymerization, polycarbonate prepared from an activated carbonate can comprise endgroups in an amount of less than 2,000 ppm, less than 1,500 ppm, or less than 1,000 ppm, based on the weight of the polycarbonate. Where only an alpha catalyst is used in the melt polymerization, a polycarbonate prepared from an activated carbonate can comprise endgroups in an amount of less than or equal to 500 ppm, less than or equal to 400 ppm, less than or equal to 300 ppm, or less than or equal to 200 ppm, based on the weight of the polycarbonate.

The reactants for the polymerization reaction using an activated aromatic carbonate can be charged into a reactor either in the solid form or in the molten form. Initial charging of reactants into a reactor and subsequent mixing of these materials under reactive conditions for polymerization can be conducted in an inert gas atmosphere such as a nitrogen atmosphere. The charging of one or more reactants can also be done at a later stage of the polymerization reaction. Mixing of the reaction mixture is accomplished by any methods known in the art, such as by stirring. Reactive conditions include time, temperature, pressure and other factors that affect polymerization of the reactants. Typically the activated aromatic carbonate is added at a mole ratio of 0.8 to 1.3, and more preferably 0.9 to 1.3, and all sub-ranges there between, relative to the total moles of monomer unit compounds. In a specific embodiment, the molar ratio of activated aromatic carbonate to monomer unit compounds is 1.013 to 1.29, specifically 1.015 to 1.028.

The melt polymerization reaction can be conducted by subjecting the reaction mixture to a series of temperature-pressure-time protocols. This can involve gradually raising the reaction temperature in stages while gradually lowering the pressure in stages. The pressure can be reduced from atmospheric pressure at the start of the reaction to 1 millibar (100 Pascals (Pa)) or lower, or to 0.1 millibar (10 Pa) or lower in several steps as the reaction approaches completion. The temperature can be varied in a stepwise fashion beginning at a temperature of the melting temperature of the reaction mixture and subsequently increased to final temperature. The reaction mixture can be heated from room temperature to 150° C. The polymerization reaction can start at a temperature of 150 to 220° C. The polymerization temperature can be up to 220° C. The polymerization reaction can then be increased to 250° C. and then further increased to a temperature of 320° C., and all sub-ranges there between. The total reaction time can be from 30 to 200 minutes and all sub-ranges there between. This procedure will generally ensure that the reactants react to give polycarbonates with the desired molecular weight, Tg and physical properties. The reaction proceeds to build the polycarbonate chain with production of ester-substituted alcohol by-product such as methyl salicylate. Efficient removal of the by-product can be achieved by different techniques such as reducing the pressure. Generally the pressure starts relatively high in the beginning of the reaction and is lowered progressively throughout the reaction and the temperature is raised throughout the reaction.

The progress of the reaction can be monitored by measuring the melt viscosity or the weight average molecular weight of the reaction mixture using techniques known in the art such as gel permeation chromatography. These properties can be measured by taking discreet samples or can be measured on-line. After the desired melt viscosity or molecular weight is reached, the final polycarbonate product can be isolated from the reactor in a solid or molten form. The polycarbonates can be made in a batch or a continuous process and can be carried out in a solvent free mode. Reactors chosen can be self-cleaning and can be configured to minimize “hot spots.” However, vented extruders similar to those that are commercially available can be used.

The polycarbonates can be prepared in an extruder in presence of one or more catalysts, wherein the carbonating agent is an activated aromatic carbonate. The reactants for the polymerization reaction can be fed to the extruder in powder or molten form. The reactants can be dry blended prior to addition to the extruder. The extruder can be equipped with pressure reducing devices (e.g., vents), which serve to remove the activated phenol by-product and thus drive the polymerization reaction toward completion. The molecular weight of the polycarbonate product can, in various aspects, be manipulated by controlling, among other factors, the feed rate of the reactants, the type of extruder, the extruder screw design and configuration, the residence time in the extruder, and the reaction temperature and the pressure reducing techniques present on the extruder. The molecular weight of the polycarbonate product can also depend upon the structures of the reactants, such as, activated aromatic carbonate, bisphenol compound(s), and the catalyst employed. Many different screw designs and extruder configurations are commercially available that use single screws, double screws, vents, back flight and forward flight zones, seals, sidestreams, and sizes. A variable for controlling the Mw when using an activated carbonate is the ratio diarylcarbonate/diol, specifically BMSC/diol. A lower ratio will give a higher molecular weight.

Decomposition by-products of the reaction that are of low molecular weight can be removed by, for example, devolatilization during reaction or extrusion to reduce the amount of such volatile compounds. The volatiles typically removed can include unreacted starting diol materials or carbonate precursor materials, but are more specifically the decomposition products of the melt-polymerization reaction.

In certain embodiments, one or more polycarbonate-polysiloxane copolymers used in the blend compositions can be produced using a continuous flow reactor. For example, in a continuous flow reactor (e.g., a tube reactor), a dihydroxy polysiloxane, dissolved in a water-immiscible solvent such as methylene chloride, can be converted by the action of phosgene and aqueous base into a mixture of mono- and bisphenol chloroformates. The mixture of chloroformates can then be treated with a catalyst, additional aqueous caustic, a dihydroxy compound (e.g., BPA), and a monophenol end capping agent to afford polycarbonate polysiloxane-copolymers. The chloroformate mixture can be transferred from the tube reactor to an interfacial polymerization reactor prior to being reacted with the dihydroxy compound (e.g., BPA).

Alternatively, in a continuous flow reactor (e.g., a tube reactor), one or more dihydroxy compounds (e.g., BPA) can be converted by the action of phosgene and aqueous base into a mixture of mono-, bis-, and oligomeric chloroformates at a pH of 6 to 8 in the presence of a water-immiscible solvent (e.g., dichloromethane) and a phase transfer catalyst. The reaction mixture can then be treated with a dihydroxy polysiloxane and stirred for 5 to 20 min at pH 10 to 13. Then, more dihydroxy compound (e.g., BPA) can be added and reacted with a carbonate precursor, such as phosgene at pH 9 to 12. Subsequently, a tertiary amine catalyst can be added and the mixture again stirred with phosgene at pH 8 to 12 until the desired polycarbonate-polysiloxane molecular weight is obtained. Again, the chloroformate mixture can be transferred from the tube reactor to an interfacial polymerization reactor to complete the polymerization process at any point after formation. The most commonly used water immiscible solvents include methylene chloride, 1,2-dichloroethane, chlorobenzene, toluene, and the like.

In certain embodiments, a polysiloxane-polycarbonate copolymer used in the blend composition can be manufactured using tube reactor processes as described in U.S. Pat. Nos. 6,833,422 and 6,723,864.

In certain embodiments, a polysiloxane-polycarbonate copolymer used in the blend composition can be manufactured as described in U.S. Pat. Nos. 6,870,013 and 7,232,865.

The compositions can comprise additional components, such as one or more additives. Suitable additives include, but are not limited to impact modifiers, UV stabilizers, colorants, flame retardants, heat stabilizers, plasticizers, lubricants, mold release agents, fillers, reinforcing agents, antioxidant agents, antistatic agents, blowing agents, anti-drip agents, and radiation stabilizers.

Various types of flame retardants can be utilized as additives. In some embodiments, the flame retardant additives include, for example, flame retardant salts such as alkali metal salts of perfluorinated C₁-C₁₆ alkyl sulfonates such as potassium perfluorobutane sulfonate (KPFS), potassium perfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate (KSS), and the like, sodium benzene sulfonate, sodium toluene sulfonate (NATS) and the like; and salts formed by reacting for example an alkali metal or alkaline earth metal (for example lithium, sodium, potassium, magnesium, calcium and barium salts) and an inorganic acid complex salt, for example, an oxo-anion, such as alkali metal and alkaline-earth metal salts of carbonic acid, such as Na₂CO₃, K₂CO₃, MgCO₃, CaCO₃, and BaCO₃ or fluoro-anion complex such as Li₃AlF₆, BaSiF₆, KBF₄. K₃AlF₆, KAlF₄, K₂SiF₆, and Na₃AlF₆ or the like. KPFS and KSS and NATS, alone or in combination with other flame retardants, are particularly useful in the compositions disclosed herein.

The flame retardant additives can include organic compounds that include phosphorus, bromine, and chlorine. Non-brominated and non-chlorinated phosphorus-containing flame retardants can be used in certain applications for regulatory reasons, for example organic phosphates and organic compounds containing phosphorus-nitrogen bonds. One type of exemplary organic phosphate is an aromatic phosphate of the formula (GO)₃P═O, wherein each G is independently an alkyl, cycloalkyl, aryl, alkylaryl, or arylalkyl group, provided that at least one G is an aromatic group. Two of the G groups can be joined together to provide a cyclic group, for example, diphenyl pentaerythritol diphosphate. Exemplary aromatic phosphates include, phenyl bis(dodecyl) phosphate, phenyl bis(neopentyl) phosphate, phenyl bis(3,5,5′-trimethylhexyl) phosphate, ethyl diphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, bis(2-ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl) phenyl phosphate, tri(nonylphenyl) phosphate, bis(dodecyl) p-tolyl phosphate, dibutyl phenyl phosphate, 2-chloroethyl diphenyl phosphate, p-tolyl bis(2,5,5′-trimethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, or the like. A specific aromatic phosphate is one in which each G is aromatic, for example, triphenyl phosphate, tricresyl phosphate, isopropylated triphenyl phosphate, and the like.

Di- or poly-functional aromatic phosphorus-containing compounds are also useful, for example, compounds of the formulas below:

wherein each G¹ is independently a hydrocarbon having 1 to 30 carbon atoms; each G² is independently a hydrocarbon or hydrocarbonoxy having 1 to 30 carbon atoms; each X^(a) represents one of the groups of formula (8) above; each X is independently a bromine or chlorine; m is 0 to 4, and n is 1 to 30. Exemplary di- or polyfunctional aromatic phosphorus-containing compounds include resorcinol tetraphenyl diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and the bis(diphenyl) phosphate of bisphenol-A, respectively (BPADP), their oligomeric and polymeric counterparts, and the like.

Exemplary flame retardant additives containing phosphorus-nitrogen bonds include phosphonitrilic chloride, phosphorus ester amides, phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, and tris(aziridinyl) phosphine oxide.

In certain embodiments, the flame retardant is not a bromine or chlorine containing composition.

In certain embodiments, the flame retardant is selected from at least one of potassium perfluorobutane sulfonate, potassium diphenylsulfone sulfonate and an organophosphorus compound. In certain embodiments, the organophosphorus compound is bisphenol A diphosphate, an oligomeric phosphate ester, or a combination thereof.

In certain embodiments, the organophosphorus compound is present in an amount effective to provide 0.1 to 1.5% of phosphorus, 0.1 to 1.2% of phosphorus, 0.6 to 1.2% of phosphorus, 0.6 to 1.0% of phosphorus, or 0.8 to 1.2% of phosphorus, based on the weight of the composition.

Flame retardant additives are generally present in amounts of 0.01 to 10 wt %, 0.02 to 5 wt %, 0.1 to 1 wt %, or 0.5 to 1.0 wt % based on 100 parts by weight of the polymer component of the thermoplastic composition.

Exemplary heat stabilizer additives include, for example, organophosphites such as triphenyl phosphite, tris-(2,6-dimethylphenyl)phosphite, tris-(mixed mono- and di-nonylphenyl)phosphite, tris(2,4-di-tert-butylphenyl)phosphite (Irgafos 168), or the like; phosphonates such as dimethylbenzene phosphonate or the like; phosphates such as trimethyl phosphate, or the like; or combinations comprising at least one of the foregoing heat stabilizers. In certain embodiments, the heat stabilizer is tetrakis(2,4-di-tert-butylphenyl)[1,1-biphenyl]-4,4′-diylbisphosphonite. Heat stabilizers are generally used in amounts of 0.0001 to 1 part by weight, based on 100 parts by weight of the polymer component of the blend composition.

Possible fillers or reinforcing agents include, for example, silicates and silica powders such as aluminum silicate (mullite), synthetic calcium silicate, zirconium silicate, fused silica, crystalline silica graphite, natural silica sand, or the like; boron powders such as boron-nitride powder, boron-silicate powders, or the like; oxides such as TiO₂, aluminum oxide, magnesium oxide, or the like; calcium sulfate (as its anhydride, dihydrate or trihydrate); calcium carbonates such as chalk, limestone, marble, synthetic precipitated calcium carbonates, or the like; talc, including fibrous, modular, needle shaped, lamellar talc, or the like; wollastonite; surface-treated wollastonite; glass spheres such as hollow and solid glass spheres, silicate spheres, cenospheres, aluminosilicate (armospheres), or the like; kaolin, including hard kaolin, soft kaolin, calcined kaolin, kaolin comprising various coatings known in the art to facilitate compatibility with the polymeric matrix, or the like; single crystal fibers or “whiskers” such as silicon carbide, alumina, boron carbide, iron, nickel, copper, or the like; fibers (including continuous and chopped fibers) such as asbestos, carbon fibers, glass fibers, such as E, A, C, ECR, R, S, D, or NE glasses, or the like; sulfides such as molybdenum sulfide, zinc sulfide or the like; barium compounds such as barium titanate, barium ferrite, barium sulfate, heavy spar, or the like; metals and metal oxides such as particulate or fibrous aluminum, bronze, zinc, copper and nickel or the like; flaked fillers such as glass flakes, flaked silicon carbide, aluminum diboride, aluminum flakes, steel flakes or the like; fibrous fillers, for example short inorganic fibers such as those derived from blends comprising at least one of aluminum silicates, aluminum oxides, magnesium oxides, and calcium sulfate hemihydrate or the like; natural fillers and reinforcements, such as wood flour obtained by pulverizing wood, fibrous products such as cellulose, cotton, sisal, jute, starch, cork flour, lignin, ground nut shells, corn, rice grain husks or the like; organic fillers such as polytetrafluoroethylene; reinforcing organic fibrous fillers formed from organic polymers capable of forming fibers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyesters, polyethylene, aromatic polyamides, aromatic polyamides, polyetherimides, polytetrafluoroethylene, acrylic resins, poly(vinyl alcohol) or the like; as well as additional fillers and reinforcing agents such as mica, clay, feldspar, flue dust, fillite, quartz, quartzite, perlite, tripoli, diatomaceous earth, carbon black, or the like, or combinations comprising at least one of the foregoing fillers or reinforcing agents.

In some embodiments, the disclosed blended thermoplastic compositions comprise a glass fiber component. In a further aspect, the glass fiber used is selected from E-glass, S-glass, AR-glass, T-glass. D-glass and R-glass. In a still further aspect, the glass fiber used is selected from E-glass, S-glass, and combinations thereof. In a still further aspect, the glass fiber is one or more E-glass materials.

The glass fibers can be sized or unsized. Sized glass fibers are coated on their surfaces with a sizing composition selected for compatibility with the polycarbonate. The sizing composition facilitates wet-out and wet-through of the polycarbonate upon the fiber strands and assists in attaining desired physical properties in the polycarbonate composition.

In various further aspects, the glass fiber is sized with a coating agent. In a further aspect, the coating agent is present in an amount from 0.1 to 5 wt % based on the weight of the glass fibers. In a still further aspect, the coating agent is present in an amount from 0.1 to 2 wt % based on the weight of the glass fibers.

In preparing the glass fibers, a number of filaments can be formed simultaneously, sized with the coating agent and then bundled into what is called a strand. Alternatively the strand itself can be first formed of filaments and then sized. The amount of sizing employed is generally that amount which is sufficient to bind the glass filaments into a continuous strand and ranges from 0.1 to 5 wt %, 0.1 to 2 wt % based on the weight of the glass fibers. Generally, this can be 1.0 wt % based on the weight of the glass filament.

In a further aspect, the glass fiber can be continuous or chopped. In a still further aspect, the glass fiber is continuous. In yet a further aspect, the glass fiber is chopped. Glass fibers in the form of chopped strands can have a length of 0.3 millimeters (mm) to 10 centimeters, specifically 0.5 millimeters to 5 centimeters, and more specifically 1.0 millimeter to 2.5 centimeters. In various further aspects, the glass fiber has a length from 0.2 mm to 20 mm. In a yet further aspect, the glass fiber has a length from 0.2 mm to 10 mm. In an even further aspect, the glass fiber has a length from 0.7 mm to 7 mm. In this area, where a thermoplastic resin is reinforced with glass fibers in a composite form, fibers having a length of 0.4 mm are generally referred to as long fibers, and shorter ones are referred to as short fibers. In a still further aspect, the glass fiber can have a length of 1 mm or longer. In yet a further aspect, the glass fiber can have a length of 2 mm or longer.

In various further aspects, the glass fiber has a round (or circular), flat, or irregular cross-section. Thus, use of non-round fiber cross sections is possible. In a still further aspect, the glass fiber has a circular cross-section. In yet further aspect, the diameter of the glass fiber is from 1 to 15 micrometers (μm). In an even further aspect, the diameter of the glass fiber is from 4 to 10 μm. In a still further aspect, the diameter of the glass fiber is from 1 to 10 μm. In a still further aspect, the glass fiber has a diameter from 7 μm to 10 μm.

The glass fiber component can be present in the composition in an amount from 5 to 40 wt %, 5 to 35 wt %, 10 to 30 wt %, 5 to 30 wt %, 5 to 20 wt %, 5 to 15%, or 10 to 20 wt %.

The composition can comprise anti-drip agents. The anti-drip agent can be a fibril forming fluoropolymer such as polytetrafluoroethylene (PTFE). The anti-drip agent can be encapsulated by a rigid copolymer as described above, for example styrene-acrylonitrile copolymer (SAN). PTFE encapsulated in SAN is known as TSAN. Encapsulated fluoropolymers can be made by polymerizing the encapsulating polymer in the presence of the fluoropolymer, for example an aqueous dispersion. TSAN can provide significant advantages over PTFE, in that TSAN can be more readily dispersed in the composition. An exemplary TSAN can comprise 50 wt % PTFE and 50 wt % SAN, based on the total weight of the encapsulated fluoropolymer. The SAN can comprise, for example, 75 wt % styrene and 25 wt % acrylonitrile based on the total weight of the copolymer. Alternatively, the fluoropolymer can be pre-blended in some manner with a second polymer, such as for, example, an aromatic polycarbonate or SAN to form an agglomerated material for use as an anti-drip agent. Either method can be used to produce an encapsulated fluoropolymer. Antidrip agents are generally used in amounts of 0.1 to 5 wt %, based on 100 parts by weight of the polymer component of the blend composition.

In certain embodiments, the anti-drip agent is TSAN. The TSAN can be present in an amount of 0.1 to 2.0 wt %, 0.1 to 1.0 wt %, 0.3 to 1.0 wt %, 0.3 to 0.7 wt %, 0.4 to 0.7 wt %, or 0.5 to 0.7 wt %, based on 100 parts by weight of the polymer component of the blend composition. In certain embodiments, the TSAN can be present in an amount of 0.3 wt %, 0.4 wt %, 0.5 wt %, 0.6 wt %, or 0.7 wt %, based on 100 parts by weight of the polymer component of the blend composition.

The blend compositions can have a combination of desired properties. The compositions can have improved mechanical, thermal, or rheological properties, or a combination thereof. The compositions can have improved optical properties. The compositions can have improved melt flow and heat resistance. The compositions can have improved melt flow, heat resistance, ductility, or impact resistance. The compositions can have improved flame retardance. Melt flow can be evaluated by, for example, melt viscosity, melt volume flow rate, or melt flow rate. Heat resistance can be evaluated by, for example. Tg, heat deformation temperature, or Vicat softening temperature. Ductility and impact resistance can be evaluated by, for example, multi axial impact, and notched Izod impact.

The blend compositions can be particularly suitable for use in the manufacture of metallized articles. An article can be molded from the blend composition and subsequently metallized. The metallized article can have a combination of desired properties. For example, the metallized article can have a desirable minimum haze onset value, metal adhesion, corrosion resistance, or combination thereof.

Melt viscosity (MV) of the blend compositions can be determined using ISO 11443 or ASTM D3835. Melt viscosity is a measurement of the rheological characteristics of a composition at temperatures and shear conditions common to processing equipment. A lower value for melt viscosity indicates that the composition flows easier. Melt viscosity can be determined at different temperatures (e.g., 260° C., 280° C., 300° C., 316° C., or 330° C.) and different shear rates (e.g., 1500 or 5000 second⁻¹). Melt viscosities are typically determined by pressing a molten composition through a die while measuring the pressure drop over the complete or part of the die. Melt viscosities can be measured by, for example, a Kayeness Capillary viscometer (e.g., with a capillary length:diameter ratio of 20:1, a capillary diameter of 1.0 millimeter, a capillary entrance angle of 180 degrees, and a dwell time of 4 minutes). Melt viscosity can be reported in Pascal-seconds (Pa-s) and the shear rate can be reported in reciprocal seconds. A melt viscosity measured at a shear rate of 5000 s⁻¹ can be referred to as a high shear melt viscosity value.

The blend compositions can have a melt viscosity of 50 to 400 MPa, 50 to 375 MPa, 50 to 350 MPa, 50 to 325 MPa, 50 to 300 MPa, 50 to 275 MPa, 50 to 250 MPa, 50 to 225 MPa, 50 to 200 MPa, 50 to 175 MPa, 50 to 150 MPa, 100 to 375 MPa, 100 to 350 MPa, 100 to 325 MPa, 100 to 300 MPa, 100 to 275 MPa, 100 to 250 MPa, 100 to 225 MPa, or 100 to 200 MPa, measured in accordance with ISO 11443 at 300° C. at a shear rate of 1500 s⁻¹, or measured in accordance with ISO 11443 at 316° C. at a shear rate of 5000 s⁻¹. The blend compositions can have a melt viscosity of less than or equal to 395 MPa, less than or equal to 390 MPa, less than or equal to 385 MPa, less than or equal to 380 MPa, less than or equal to 375 MPa, less than or equal to 370 MPa, less than or equal to 365 MPa, less than or equal to 360 MPa, less than or equal to 355 MPa, less than or equal to 350 MPa, less than or equal to 345 MPa, less than or equal to 340 MPa, less than or equal to 335 MPa, less than or equal to 330 MPa, less than or equal to 325 MPa, less than or equal to 320 MPa, less than or equal to 315 MPa, less than or equal to 310 MPa, less than or equal to 305 MPa, less than or equal to 300 MPa, less than or equal to 295 MPa, less than or equal to 290 MPa, less than or equal to 285 MPa, less than or equal to 280 MPa, less than or equal to 275 MPa, less than or equal to 270 MPa, less than or equal to 265 MPa, less than or equal to 260 MPa, less than or equal to 255 MPa, less than or equal to 250 MPa, less than or equal to 245 MPa, less than or equal to 240 MPa, less than or equal to 235 MPa, less than or equal to 230 MPa, less than or equal to 225 MPa, less than or equal to 220 MPa, less than or equal to 215 MPa, less than or equal to 210 MPa, less than or equal to 205 MPa, less than or equal to 200 MPa, less than or equal to 195 MPa, less than or equal to 190 MPa, less than or equal to 185 MPa, less than or equal to 180 MPa, less than or equal to 175 MPa, less than or equal to 170 MPa, less than or equal to 165 MPa, less than or equal to 160 MPa, less than or equal to 155 MPa, less than or equal to 150 MPa, less than or equal to 145 MPa, less than or equal to 140 MPa, less than or equal to 135 MPa, less than or equal to 130 MPa, less than or equal to 125 MPa, less than or equal to 120 MPa, less than or equal to 115 MPa, less than or equal to 110 MPa, less than or equal to 105 MPa, less than or equal to 100 MPa, less than or equal to 95 MPa, less than or equal to 90 MPa, less than or equal to 85 MPa, less than or equal to 80 MPa, less than or equal to 75 MPa, less than or equal to 70 MPa, less than or equal to 65 MPa, less than or equal to 60 MPa, less than or equal to 55 MPa, or less than or equal to 50 MPa, measured in accordance with ISO 11443 at 300° C. at a shear rate of 1500 s⁻¹, or measured in accordance with ISO 11443 at 316° C. at a shear rate of 5000 s⁻¹.

Melt volume flow rate (MVR) of the blend compositions can be determined using ISO 1133 or ASTM D1238. MVR measures the volume of a composition extruded through an orifice at a prescribed temperature and load over a prescribed time period. The higher the MVR value of a polymer composition at a specific temperature, the greater the flow of that composition at that specific temperature.

MVR can be measured, for example, by packing a small amount of polymer composition into an extruder barrel of an extruder. The composition can be preheated for a specified amount of time at a particular temperature (the test temperature is usually set at or slightly above the melting region of the material being characterized). After preheating the composition, a particular weight (e.g., a 2.16 kg weight) can be introduced to a piston, which acts as the medium that causes extrusion of the molten polymer composition. The weight exerts a force on the piston and thereby the molten polymer composition, and the molten composition flows through the dye wherein the displacement of the molten composition is measured in cubic centimeters per over time such as 10 minutes (cm³/10 min).

The compositions can have a MVR of 2 to 300 cm³/10 min. 2 to 200 cm³/10 min, 2 to 100 cm³/10 min, 10 to 300 cm³/10 min. 20 to 300 cm³/10 min, 30 to 300 cm³/10 min. 40 to 300 cm³/10 min, 50 to 300 cm³/10 min, 60 to 300 cm³/10 min. 70 to 300 cm³/10 min, 80 to 300 cm³/10 min, 90 to 300 cm³/10 min, 100 to 300 cm³/10 min, 50 to 200 cm³/10 min, 75 to 175 cm³/10 min, or 100 to 150 cm³/10 min, using the ISO 1133 method, 2.16 kg load, 330° C. temperature, 360 second dwell. The compositions can have a MVR of 5 cm³/10 min or greater, 10 cm³/10 min or greater, 20 cm³/10 min or greater, 30 cm³/10 min or greater, 40 cm³/10 min or greater, 50 cm³/10 min or greater, 60 cm³/10 min or greater, 70 cm³/10 min or greater, 80 cm³/10 min or greater, 90 cm³/10 min or greater, 100 cm³/10 min or greater, 110 cm³/10 min or greater, 120 cm³/10 min or greater, 130 cm³/10 min or greater, 140 cm³/10 min or greater, 150 cm³/10 min or greater, 160 cm³/10 min or greater, 170 cm³/10 min or greater, 180 cm³/10 min or greater, 190 cm³/10 min or greater, 200 cm³/1) min or greater, 210 cm³/10 min or greater, 220 cm³/10 min or greater, 230 cm³/10 min or greater, 240 cm³/10 min or greater, 250 cm³/10 min or greater, 260 cm³/10 min or greater, 270 cm³/10 min or greater, 280 cm³/10 min or greater, 290 cm³/10 min or greater, or 300 cm³/10 min or greater, using the ISO 1133 method, 2.16 kg load, 330° C. temperature, 360 second dwell.

the Tg of the blended compositions can be determined using DSC, for example, with a heating rate of 10° C./minute and using the second heating curve for Tg determination.

The blend compositions can have a Tg of greater than or equal to 120° C., greater than or equal to 125° C., greater than or equal to 130° C., greater than or equal to 135° C., greater than or equal to 140° C., greater than or equal to 145° C., greater than or equal to 150° C., greater than or equal to 155° C., greater than or equal to 160° C., greater than or equal to 165° C., greater than or equal to 170° C., greater than or equal to 175° C., greater than or equal to 180° C., greater than or equal to 185° C., greater than or equal to 190° C., greater than or equal to 200° C., greater than or equal to 210° C., greater than or equal to 220° C., greater than or equal to 230° C., greater than or equal to 240° C., greater than or equal to 250° C., greater than or equal to 260° C., greater than or equal to 270° C., greater than or equal to 280° C., greater than or equal to 290° C., or greater than or equal to 300° C., as measured using a differential scanning calorimetry method. The compositions can have Tgs ranging from 120 to 230° C., 140 to 185° C., 145 to 18° C., 150 to 175° C., 155 to 170° C., or 160 to 165° C. The compositions can have a Tg of 150° C., 151° C., 152° C., 153° C., 154° C., 155° C., 156° C., 157° C., 158° C., 159° C., 160° C., 161° C., 162° C., 163° C., 164° C., 165° C., 166° C., 167° C., 168° C., 169° C., 170° C., 171° C., 172° C., 173° C., 174° C., or 175° C.

Heat deflection temperature or heat distortion temperature (HDT) of the blended compositions can be determined according to ISO 75 or ASTM D648. HDT is a measure of heat resistance and is an indicator of the ability of a material to withstand deformation from heat over time. A higher iHDT value indicates better heat resistance. Measurements can be performed on molded ISO bars (80×10×4 mm) preconditioned at 23° C. and 50% relative humidity for 48 hrs. The heating medium of the HDT equipment can be mineral oil. Measurements can be performed in duplicate and the average value reported.

The blend compositions can have an HDT of greater than or equal to 120° C., greater than or equal to 125° C., greater than or equal to 130° C., greater than or equal to 135° C., greater than or equal to 140° C., greater than or equal to 145° C., greater than or equal to 1500° C., greater than or equal to 155° C., greater than or equal to 160° C., greater than or equal to 165° C., greater than or equal to 170° C., greater than or equal to 175° C., greater than or equal to 180° C., greater than or equal to 185° C., greater than or equal to 190° C., greater than or equal to 200° C., greater than or equal to 210° C., greater than or equal to 220° C., greater than or equal to 230° C., greater than or equal to 240° C., greater than or equal to 250° C., greater than or equal to 260° C., greater than or equal to 270° C., greater than or equal to 280° C., greater than or equal to 290° C., or greater than or equal to 300° C., measured at 0.45 MPa stress or 1.8 MPa stress in accordance with ISO 75. The compositions can have heat deflection temperatures ranging from 120 to 230° C., 140 to 185° C., 145 to 180° C., 150 to 175° C., 155 to 17° C., or 160 to 165° C., measured at 0.45 MPa stress or 1.8 MPa stress in accordance with ISO 75. The compositions can have a heat deflection temperature of 150° C., 151° C., 152° C., 153° C., 154° C., 155° C., 156° C., 157° C., 158° C., 159° C., 160° C., 161° C., 162° C., 163° C., 164° C., 165° C., 166° C., 167° C., 168° C., 169° C., 170° C., 171° C., 172° C., 173° C., 174° C., or 175° C., measured at 0.45 MPa stress or 1.8 MPa stress in accordance with ISO 75.

Multiaxial impact testing (MAI) can be performed according to ISO 6603 or ASTM D3763. This procedure provides information on how a material behaves under multiaxial deformation conditions. The multiaxial impact value indicates the amount of energy the material absorbs during the test; a higher value generally indicates a better result. Impact properties that can be reported include Energy to Maximum Load. Energy to Failure, and Average Total Energy, all expressed in units of Joules. Ductility of tested parts can be expressed in percent (% D) based on whether the part fractured in a brittle or ductile manner.

Multiaxial impact can be measured using injection molded plaques (e.g., disks 3.2 mm thick and 10 centimeters in diameter). The plaques can be prepared using standard molding conditions or abusive molding conditions. Standard molding conditions can refer to a barrel temperature of 580° F. and a residence time of 35 seconds. Abusive molding conditions can refer to a barrel temperature of 580-620° F. and a residence time of 120 seconds. Abusive molding conditions can refer to conditions where the composition dwells in the molder barrel for an extended period of time and under elevated molding temperatures that can cause thermal degradation of one or more polymers in the composition. An apparatus, such as a Dynatup, can be used to evaluate multiaxial impact, and can have a tup of 10 mm, 12.5 mm, or 20 mm. The impact velocity can be 4.4 m/s. Measurements can be conducted at various temperatures (e.g., 23° C., 0° C., −30° C.).

The blend compositions can have an Energy to Maximum Load of 10 to 250 Joules (J), 50 to 200 J, or 100 to 150 J, at 23° C., 0° C., or −30° C., molded under standard molding conditions. The blend compositions can have an Energy to Maximum Load of greater than or equal to 10 J, greater than or equal to 25 J, greater than or equal to 50 J, greater than or equal to 75 J, greater than or equal to 100 J, greater than or equal to 125 J, greater than or equal to 150 J, greater than or equal to 175 J, or greater than or equal to 200 J, at 23° C., 0° C., or −30° C., molded under standard molding conditions.

The blend compositions can have an Energy to Maximum Load of 10 to 250 J, 50 to 200 J, or 100 to 150 J, at 23° C., 0° C., or −30° C., molded under abusive molding conditions. The blend compositions can have an Energy to Maximum Load of greater than or equal to 10 J, greater than or equal to 25 J, greater than or equal to 50 J, greater than or equal to 75 J, greater than or equal to 100 J, greater than or equal to 125 J, greater than or equal to 150 J, greater than or equal to 175 J, or greater than or equal to 200 J, at 23° C., 0° C., or −30° C., molded under abusive molding conditions.

The blend compositions can have an Energy to Failure of 10 J to 250 J, 50 J to 200 J, or 100 J to 150 J, at 23° C., 0° C., or −30° C., molded under standard molding conditions. The blend compositions can have an Energy to Failure of greater than or equal to 10 J, greater than or equal to 25 J, greater than or equal to 50 J, greater than or equal to 75 J, greater than or equal to 100 J, greater than or equal to 125 J, greater than or equal to 150 J, greater than or equal to 175 J, or greater than or equal to 200 J, at 23° C., 0° C., or −30° C., molded under standard molding conditions.

The blend compositions can have an Energy to Failure of 10 J to 250 J, 50 J to 200 J, or 100 J to 150 J, at 23° C., 0° C., or −30° C., molded under abusive molding conditions. The blend compositions can have an Energy to Failure of greater than or equal to 10 J, greater than or equal to 25 J, greater than or equal to 50 J, greater than or equal to 75 J, greater than or equal to 100 J, greater than or equal to 125 J, greater than or equal to 150 J, greater than or equal to 175 J, or greater than or equal to 200 J, at 23° C., 0° C., or −30° C., molded under abusive molding conditions.

The blend compositions can have an Average Total Energy of 10 to 250 J, 50 to 200 J, or 100 to 150 J, at 23° C., 0° C., or −30° C., molded under standard molding conditions. The blend compositions can have an Average Total Energy of greater than or equal to 10 J, greater than or equal to 25 J, greater than or equal to 50 J, greater than or equal to 75 J, greater than or equal to 100 J, greater than or equal to 125 J, greater than or equal to 150 J, greater than or equal to 175 J, or greater than or equal to 200 J, at 23° C., 0° C., or −30° C., molded under standard molding conditions.

The blend compositions can have an Average Total Energy of 10 to 250 J, 50 to 200 J, or 100 to 150 J, at 23° C., 0° C., or −30° C., molded under abusive molding conditions. The blend compositions can have an Average Total Energy of greater than or equal to 10 J, greater than or equal to 25 J, greater than or equal to 50 J, greater than or equal to 75 J, greater than or equal to 100 J, greater than or equal to 125 J, greater than or equal to 150 J, greater than or equal to 175 J, or greater than or equal to 200 J, at 23° C., 0° C., or −30° C., molded under abusive molding conditions.

The blend compositions can possess a ductility of greater than or equal to 50%, greater than or equal to 55%, greater than or equal to 60%, greater than or equal to 65%, greater than or equal to 70%, greater than or equal to 75%, greater than or equal to 80%, greater than or equal to 85%, greater than or equal to 90%, greater than or equal to 95%, or 100% in a multiaxial impact test at 23° C., 0° C., or −30° C., molded under standard molding conditions.

The blend compositions can possess a ductility of greater than or equal to 50%, greater than or equal to 55%, greater than or equal to 60%, greater than or equal to 65%, greater than or equal to 70%, greater than or equal to 75%, greater than or equal to 80%, greater than or equal to 85%, greater than or equal to 90%, greater than or equal to 95%, or 100% in a multiaxial impact test at 23° C., 0° C., or −30° C., molded under abusive molding conditions.

The blend compositions can have a notched izod impact energy (NII). A higher NII value indicates better impact strength. The polycarbonate compositions can have a notched izod impact energy (NII) of greater than or equal to 4 Joules per meter (J/m), greater than or equal to 5 J/m, greater than or equal to 6 J/m, greater than or equal to 7 J/m, greater than or equal to 8 J/m, greater than or equal to 9 J/m, greater than or equal to 10 J/m, greater than or equal to 11 J/m, greater than or equal to 12 J/m, greater than or equal to 13 J/m, greater than or equal to 14 J/m, greater than or equal to 15 J/m, greater than or equal to 16 J/m, greater than or equal to 17 J/m, greater than or equal to 18 J/m, greater than or equal to 19 J/m, greater than or equal to 20 J/m, greater than or equal to 21 J/m, greater than or equal to 22 Jim, greater than or equal to 23 J/m, greater than or equal to 24 J/m, greater than or equal to 25 J/m, greater than or equal to 26 J/m, greater than or equal to 27 J/m, greater than or equal to 28 J/m, greater than or equal to 29 J/m, greater than or equal to 30 J/m, greater than or equal to 31 J/m, greater than or equal to 32 J/m, greater than or equal to 33 J/m, greater than or equal to 34 J/m, greater than or equal to 35 J/m, greater than or equal to 36 J/m, greater than or equal to 37 J/m, greater than or equal to 38 J/m, greater than or equal to 39 J/m, greater than or equal to 40 J/m, greater than or equal to 41 J/m, greater than or equal to 42 J/m, greater than or equal to 43 J/m, greater than or equal to 44 J/m, greater than or equal to 45 J/m, greater than or equal to 46 J/m, greater than or equal to 47 J/nm greater than or equal to 48 J/m, greater than or equal to 49 J/m, greater than or equal to 50 J/m, greater than or equal to 51 J/m, greater than or equal to 52 J/m, greater than or equal to 53 J/m, greater than or equal to 54 J/m, greater than or equal to 55 J/m, greater than or equal to 56 J/m, greater than or equal to 57 J/m, greater than or equal to 58 J/m, greater than or equal to 59 J/m, or greater than or equal to 60 J/m, measured at 23° C., 0° C., or −30° C. according to ASTM D 256.

The blend compositions can possess a ductility of greater than or equal to 50%, greater than or equal to 55%, greater than or equal to 60%, greater than or equal to 65%, greater than or equal to 70%, greater than or equal to 75%, greater than or equal to 80%, greater than or equal to 85%, greater than or equal to 90%, greater than or equal to 95%, or 100% in a notched izod impact test at −20° C., −15° C., −10° C., 0° C., 5° C., 10° C., 15° C., 20° C., 23° C., 25° C., 30° C., or 35° C. at a thickness of 3.2 mm according to ASTM D 256.

Flammability tests can be performed following the procedure of Underwriter's Laboratory Bulletin 94 entitled “Tests for Flammability of Plastic Materials, UL94.” According to this procedure, materials can be classified as V-0, V-1 or V-2 on the basis of the test results obtained for samples of 1.5 to 2.0 millimeter thickness. The samples are made according to the UL94 test procedure using standard ASTM molding criteria. The criteria for each of the flammability classifications tested are described below.

V0: In a sample placed so that its long axis is 180 degrees to the flame, the average period of flaming and smoldering after removing the igniting flame does not exceed five seconds and none of the vertically placed samples produces drips of burning particles that ignite absorbent cotton, and no specimen burns up to the holding clamp after flame or after glow. Five bars flame out time (FOT) is the sum of the flame out time for five bars each lit twice for ten (10) seconds each, for a maximum flame out time of 50 seconds. FOT1 is the average flame out time after the first light. FOT2 is the average flame out time after the second light.

V-1, V-2: In a sample placed so that its long axis is 180 degrees to the flame, the average period of flaming and smoldering after removing the igniting flame does not exceed twenty-five seconds and, for a V-1 rating, none of the vertically placed samples produces drips of burning particles that ignite absorbent cotton. The V2 standard is the same as V-1, except that flaming drips that ignite the cotton are permitted. Five bar flame out time (FOT) is the sum of the flame out time for five bars, each lit twice for ten (10) seconds each, for a maximum flame out time of 250 seconds.

The data can also be analyzed by calculating the average flame out time, standard deviation of the flame out time and the total number of drips, and by using statistical methods to convert that data to a prediction of the probability of first time pass, or “p(FTP)”, that a particular sample formulation would achieve a “pass” rating in the conventional UL94 V0 or V1 testing of 5 bars. The probability of a first time pass on a first submission (pFTP) can be determined according to the formula: PFTP=(P _(t1>mbt,n=0) ×P _(t2>mbt,n=0) ×P _(total<=mtbt) ×P _(drip,n=0)) where P_(t1>mbt, n=0) is the probability that no first burn time exceeds a maximum burn time value, P_(t2>mbt, n=0) is the probability that no second burn time exceeds a maximum burn time value, P_(total<=mtbt) is the probability that the sum of the burn times is less than or equal to a maximum total burn time value, and P_(drip, n=0) is the probability that no specimen exhibits dripping during the flame test. First and second burn time refer to burn times after a first and second application of the flame, respectively.

The probability that no first burn time exceeds a maximum burn time value, P_(t1>mbt, n=0), can be determined from the formula: P_(t1>mbt, n=0)=(1−P_(t1>mbt))⁵ where P_(t1>mbt) is the area under the log normal distribution curve for t1>mbt, and where the exponent “5” relates to the number of bars tested. The probability that no second burn time exceeds a maximum burn time value can be determined from the formula: P_(t2>mbt, n=0)=(1−P_(t2>mbt)) where P_(t2>mbt) is the area under the normal distribution curve for t2>mbt. As above, the mean and standard deviation of the burn time data set are used to calculate the normal distribution curve. For the UL-94 V-0 rating, the maximum burn time is 10 seconds. For a V-1 or V-2 rating the maximum burn time is 30 seconds. The probability P_(drip, n=0) that no specimen exhibits dripping during the flame test is an attribute function, estimated by: (1−P_(drip))⁵ where P_(drip)=(the number of bars that drip/the number of bars tested).

The probability P_(total<=mtbt) that the sum of the burn times is less than or equal to a maximum total burn time value can be determined from a normal distribution curve of simulated 5-bar total burn times. The distribution can be generated from a Monte Carlo simulation of 1000 sets of five bars using the distribution for the burn time data determined above. Techniques for Monte Carlo simulation are well known in the art. A normal distribution curve for 5-bar total burn times can be generated using the mean and standard deviation of the simulated 1000 sets. Therefore, P_(total<=mtbt) can be determined from the area under a log normal distribution curve of a set of 1000 Monte Carlo simulated 5-bar total burn time for total<=maximum total burn time. For the UL-94 V-0 rating, the maximum total burn time is 50 seconds. For a V-1 or V-2 rating, the maximum total burn time is 250 seconds.

Preferably, p(FTP) is as close to 1 as possible, for example, greater than or equal to 0.6, or greater than or equal to 0.7, or greater than or equal to 0.8 or, more specifically, greater than or equal to 0.85, for maximum flame-retardant performance in UL testing. The p(FTP)>0.7, and specifically, p(FTP)>0.85, is a more stringent standard than merely specifying compliance with the referenced V-0 or V-1 test.

The compositions disclosed herein can be manufactured by various methods. For example, a composition can be first mixed in a high speed HENSCHEL-Mixer. Other low shear processes, including but not limited to hand mixing, can also accomplish this blending. The mixed composition can then be fed into the throat of a single or twin-screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding directly into the extruder at the throat or downstream through a side-stuffer. Additives can also be compounded into a master-batch with a desired polymeric resin and fed into the extruder. The extruder can be generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate can be immediately quenched in a water batch and pelletized. The pellets, so prepared, when cutting the extrudate can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.

In certain embodiments, the compositions can undergo a reactive extrusion process, as described herein, by injection of a redistribution catalyst into the extruder during the extrusion process.

Shaped, formed, or molded articles comprising the polycarbonate compositions are also provided. The article can be a metallized article. The article can be metallized with, for example, chrome, nickel, or aluminum. The article can optionally include an intervening base coat between the molded article and the metal.

Articles that can be prepared using the polycarbonate compositions include, for example, automotive, aircraft, and watercraft exterior and interior components. Exemplary articles include, but are not limited to, instrument panels, overhead consoles, interior trim, center consoles, panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, fascia, grilles, minor housings, pillar appliqués, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, headlamps, tail lamps, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, circuit breakers, electrical and electronic housings, and running boards, or any combination thereof. In certain embodiments, the article is a metallized automotive bezel.

Exemplary articles include, for example, a medical device, a display device, a projector lens, a heat shield, a lighting source enclosure, a lighting source lens, a computer monitor screen, a laptop screen, a liquid crystal display screen, an organic light-emitting diode screen, computer and business machine housings (e.g., housings for monitors, handheld electronic device housings such as housings for cell phones), electrical connectors, components of lighting fixtures, ornaments, home appliances, roofs, greenhouses, sun rooms, swimming pool enclosures, electronic device casings and signs and the like.

Exemplary articles include, for example, enclosures, housings, panels, and parts for outdoor vehicles and devices; enclosures for electrical and telecommunication devices; outdoor furniture; aircraft components; boats and marine equipment, including trim, enclosures, and housings; outboard motor housings; depth finder housings; personal water-craft; jet-skis; pools; spas; hot tubs; steps; step coverings; building and construction applications such as glazing, roofs, windows, floors, decorative window furnishings or treatments; treated glass covers for pictures, paintings, posters, and like display items; wall panels, and doors; counter tops; protected graphics; outdoor and indoor signs; enclosures, housings, panels, and parts for automatic teller machines (ATM); computer; desk-top computer; portable computer; lap-top computer; hand held computer housings; monitor; printer; keyboards; FAX machine; copier; telephone; phone bezels; mobile phone; radio sender; radio receiver; enclosures, housings, panels, and parts for lawn and garden tractors, lawn mowers, and tools, including lawn and garden tools; window and door trim; sports equipment and toys; enclosures, housings, panels, and parts for snowmobiles; recreational vehicle panels and components; playground equipment; shoe laces; articles made from plastic-wood combinations; golf course markers; utility pit covers; light fixtures; lighting appliances; network interface device housings; transformer housings; air conditioner housings; cladding or seating for public transportation; cladding or seating for trains, subways, or buses; meter housings; antenna housings; cladding for satellite dishes; coated helmets and personal protective equipment; coated synthetic or natural textiles; coated painted articles; coated dyed articles; coated fluorescent articles; coated foam articles; and like applications.

The article can be an automotive bezel, an automobile headlamp lens (e.g., an outer headlamp lens or an inner headlamp lens), or a headlamp assembly comprising: a headlamp lens; a headlamp reflector; a bezel; and a housing. The headlamp assembly can further comprise a tungsten-halogen, a halogen infrared reflective, or a high-intensity discharge light source.

In certain embodiments, an article molded from the thermoplastic composition (via, e.g., injection molding) has no surface defects visible to the eye on a surface thereof. In certain embodiments, when a surface of the molded article is metallized, the metallized surface has no surface defects visible to the eye. A base coat can be present between the article and the metallized surface, or the surface of the article can be directly metallized without a base coat.

In certain embodiments, a surface of an article molded from the thermoplastic composition (via, e.g., injection molding) exhibits a gloss of greater than 95 units, measured at 20 degrees using a trigloss meter. In certain embodiments, when a surface of the molded article is metallized, the metallized surface has a gloss of greater than 1000 units, greater than 1100 units, greater than 1200 units, greater than 1300 units, greater than 1400 units, greater than 1500 units, greater than 1600 units, or greater than 1700 units, measured at 20 degrees using a trigloss meter. A base coat can be present between the article and the metallized surface, or the surface of the article can be directly metallized without a base coat.

The gloss of the molded articles can be further heat stable. For example, there is provided an article formed from the compositions (via. e.g., injection molding), and having a metallized surface, wherein the metallized surface retains 80% or more, 85% or more, 90% or more, or 95% or more of its gloss after heat aging at 150° C. for 1 hour, measured at 20 degrees using a trigloss meter. A base coat can be present between the article and the metallized surface, or the surface of the article can be directly metallized without a base coat.

There is also provided an article formed from the compositions (via, e.g., injection molding), and having a metallized surface, wherein the metallized surface retains 80% or more, 85% or more, 90% or more, or 95% or more of its gloss after heat aging at 160° C. for 1 hour, measured at 20 degrees using a trigloss meter. A base coat can be present between the article and the metallized surface, or the surface of the article can be directly metallized without a base coat.

In certain embodiments, there is provided an article formed from the compositions, specifically a composition having up to 2 wt % of a particulate filler, or no filler, and having a metallized surface, wherein the metallized surface retains 80% or more, 85% or more, 90% or more, or 95% or more of its gloss after heat aging at 150° C. for 1 hour, measured at 20 degrees using a tri gloss meter. An undercoat can be present between the article and the metallized surface, or a surface of the article can be directly metallized.

In certain embodiments, there is provided an article formed from the compositions, where the compositions include one or more additives such as, for example, antioxidants, flame retardants, heat stabilizers, light stabilizers, antistatic agents, colorants, and the like. An antioxidant stabilizer composition can be used, such as for example a hindered diol stabilizer, a thioester stabilizer, an amine stabilizer, a phosphite stabilizer, or a combination comprising at least one of the foregoing types of stabilizers.

The polycarbonate compositions can be molded into useful shaped articles by a variety of methods, such as injection molding, extrusion, rotational molding, compression molding, blow molding, sheet or film extrusion, profile extrusion, gas assist molding, structural foam molding, and thermoforming. Additional fabrication operations for preparing the articles include, but are not limited to, molding, in-mold decoration, baking in a paint oven, lamination, metallization, and thermoforming.

Various types of gates can be employed for preparing molded articles, such as for example, side gates, spoke gates, pin gates, submarine gates, film gates, disk gates, or any combination thereof. Considerations in gating include part design, flow, end use requirements, and location of in-mold graphics. The standard guidelines of traditional gating can apply, along with several extra considerations. For example, one gate can be used whenever possible to minimize the potential for wrinkling a film. Gates can be located away from end-use impact as well as to provide flow from thick to thin sections to minimize weld lines. Gates can also be located at right angles to a runner to minimize jetting, splay and gate blush. Large parts requiring multiple gates can include gate positions close enough together to reduce pressure loss. Sequential gating can be used to prevent folding of a film at weld lines. Gate land lengths can be kept as short as possible. An impinging gate can be used to ensure that the incoming flow is directed against the cavity wall or core to prevent jetting. Venting (particularly full perimeter venting) can be accomplished by knock outs, cores, and parting lines and can be used whenever possible to avoid trapped gas that can burn and rupture a film. In addition, flow restrictions near gate areas can increase the potential for wash out due to increased shear. If bosses, core shutoffs, etc., are needed near a gate, rounded features or corners can be used to reduce shear. Gating for distributing injection pressure over a large area, thus reducing the shear forces at the gate, include fan gates and submarine gates that enter the part via a rib. It is common to add a puddle or thicker area at a gate entrance point for gates like valve gates, hot drops, and cashew gates.

The article can be produced by a manufacturing process. The process can include (a) providing a polycarbonate composition as disclosed herein; (b) melting the composition, for example at 200-400° C., 225-350° C., or 270-300° C. in an extruder; (c) extruding the composition; and (d) isolating the composition. The article can be further produced by (e) drying the composition and (1) melt forming the composition.

A method of preparing a metallized article can include molding a composition into a predetermined mold dimensioned to a selected article as described above; and subjecting the molded article to a metallization process (e.g., vacuum deposition processes, vacuum sputtering processes, or a combination thereof). An exemplary method can include the general steps of an initial pump down on a molded article in a vacuum chamber; glow discharge/plasma clear; and metal deposition and application of a topcoat. Exemplary metals for metallization include, but are not limited to, chrome, nickel, and aluminum. The surface of the molded item can be cleaned and degreased before vapor deposition in order to increase adhesion. A base coat can optionally be applied before metallization, for example, to improve metal layer adhesion. In certain embodiments, the metallized article is manufactured without applying a base coat prior to metallization.

A method of preparing a metallized article can include molding an article and subsequently metallizing the article using a physical vapor deposition (PVI) metallization process. During the metallization process, high vacuum can be applied and the article treated with plasma to create a polar surface to enhance adhesion. Subsequent to plasma treatment, a metal (e.g., aluminum) can be vaporized to deposit a selected thickness (e.g., 100 nm to 150 nm) of metal layer onto the article surface. This step can be followed with applying a plasma-deposit siloxane hardcoat of selected thickness (e.g., 50 nm) to protect the metal layer against oxidation and scratches.

A method of preparing a metallized article can include mounting an article (e.g., on a rack) after molding and cleaning the article (e.g., with ionized air); positioning the article in a vacuum chamber; and metallizing the article under reduced pressure (e.g., using physical vapor deposition). After metallization, a protective transparent layer can be applied to the metallized article. For example, hexamethyldisiloxane (HMDS) or SiOx can be applied in the vacuum chamber, or a silicone hard coat can be applied outside the vacuum chamber. In certain embodiments, the metallization process includes the steps of forepumping, glow discharge, high vacuum pumping, coating (thermal coating in high vacuum), cool-down time, protective coating (glow discharge polymerization), venting, and charging.

A method of preparing a metallized article can include drying a molded article (e.g., in a circulating oven) at a selected temperature (e.g., 275° F.) and time (e.g., 8 hours). The molded article can optionally be placed in a bag (e.g., ziplock bag) and heat sealed to minimize moisture uptake prior to metallization. The molded article can be placed on an open rack in a controlled environment at a selected temperature (e.g., 23° C.), and humidity (e.g., 50% relative humidity), and for a selected time (e.g., 1 to 5 days). The molded article can then be metallized (e.g., with evaporative metallization or sputtering). Evaporative metallization can include the process of having a metal resistively heated under deep vacuum that is subsequently allowed to cool onto exposed surfaces.

A method of preparing a metallized article can include providing an article into a vacuum chamber and pumping down the vacuum chamber (e.g., using a roughing pump to obtain a pressure of 8×10⁻² mbar, following by a fine pump to achieve a pressure of 1×10⁻³ mbar). After the pump down, the pressure can be increased (e.g., to 2.5×10⁻² mbar) by adding a selected gas (e.g., argon or an oxygen/argon mixture) into the chamber. A glow discharge plasma clean can be implemented (e.g., at 40 kHz/3 kW) to prepare the article surface for metallization. The chamber can then be pumped down to a suitable pressure (e.g., 1.3×10⁻⁴) prior to metallization. Next, metal deposition (e.g., aluminum deposition) can be implemented for a suitable time (e.g., 1 minute) to apply a selected thickness of metal (e.g., 70 to 100 nm). Following evaporative deposition of the metal, the pressure can be increased in the vacuum chamber (e.g., to 4×10⁻² mbar) in preparation for topcoat application (e.g., HMDS topcoat). The topcoat material (e.g., HDMS) can be introduced into the vacuum chamber to apply a protective layer (e.g., a 45 nm protective HMDS layer) under glow discharge conditions (e.g., for 180 min).

A method of preparing a metallized article can include an initial pump down (e.g., less than 10⁻⁵ Mbar); glow discharge pretreatment (e.g., using air, pressure of 10⁻¹ Mbar, voltage 4 Kv, time 1 minute); pump down (e.g., less than 10⁻⁵ Mbar); thermal aluminum evaporation (e.g., in 1 minute); and plasil protective layer application under glow discharge (e.g., using air, pressure 10⁻¹ Mbar, voltage 4Kv, time 1 minute).

A method of preparing a metallized article can provide an article with a metal layer thickness of, for example, 10 to 300 nanometers (nm), 50 to 200 nm, 75 to 175 nm, 100 to 150 nm, or 70 to 100 nm. The thickness of the metal layer (e.g., an aluminum layer) can be 50 nm, 55 nm, 60 nm, 65 nm, 70 nm, 75 nm, 80 nm, 90 nm, 95 nm, 100 nm, 105 nm, 110 nm, 115 nm, 120 nm, 125 nm, 130 nm, 135 nm, 140 nm, 150, 155 nm, 150, 155 nm, 160 nm 165 nm, 170 nm, 175 nm, 180 nm, 185 nm, 190 nm, 195 nm, or 200 nm.

A topcoat (e.g., siloxane hard-coat) can be applied to a metallized article, the topcoat having a thickness of, for example, 5 to 150 nm, 10 to 100 nm, 30 to 75 nm, 40 to 60 nm, or 45 to 55 nm. The thickness of the topcoat can be 10 nm, 15 nm, 20 nm, 25 nm, 30 nm, 35 nm, 40 nm, 45 nm, 50 nm, 55 nm, 60 nm, 65 nm, 70 nm, 75 nm, 80 nm, 85 nm, 90 nm, 95 nm, or 100 nm.

A wide variety of articles can be manufactured using the disclosed compositions, including components for lighting articles, particularly optical reflectors. The optical reflectors can be used in automotive headlamps, headlamp bezels, headlight extensions and headlamp reflectors, for indoor illumination, for vehicle interior illumination, and the like.

In the manufacture of an optical reflector, the thermoplastic composition can be molded, an optional base coat can be applied to a surface of the article, followed by metallization of the surface. In certain embodiments, a base coat is not applied to a surface of the molded article prior to metallization. The surfaces of the molded items are smooth and good gloss can be obtained even by direct metal vapor deposition without treating the molded item with primer. Moreover, because the release properties of the molded item during injection molding are good, the surface properties of the molded item are superior without replication of mold unevenness.

The articles, in particular lighting articles, can have one or more of the following properties: very low mold shrinkage; good surface gloss even when metal layers are directly vapor deposited; no residue on the mold after long molding runs; and the vapor deposited surfaces do not become cloudy or have rainbow patterns even on heating of the vapor deposited surface. The articles further can have good heat stability.

The polycarbonate blend compositions preferably have one or more beneficial properties for the production of heat resistant articles (e.g., automotive bezels), and in particular, metallizable heat resistant articles. The polycarbonate blend compositions can exhibit a combination of desirable properties, and in particular, thermal, mechanical, and rheological properties. For example, the polycarbonate blend compositions can exhibit a combination of one or more of heat resistance, impact resistance, low temperature ductility, low melt viscosity, good melt stability, and low mold stress. The compositions can be used for the production of articles, including thin-walled articles, having superior thermal and mechanical performance compared to currently available technologies. The compositions can be particularly suitable for use in preparing metallized articles, and in particular, metallized articles exhibiting desirable haze onset temperatures, good metal adhesion to the article, and high corrosion resistance.

The polycarbonate blend compositions can include one or more components configured to enhance one or more of the thermal, mechanical, rheological, and metallization performance of the blend compositions. It has been unexpectedly found that the compositions disclosed herein can be prepared having a combination of flame retardant, thermal, mechanical, and rheological properties that exceed currently available technologies. In addition, the compositions can be used to prepare metallized articles to meet design demands.

The polycarbonate blend compositions can include one or more high heat polycarbonates to enhance one or more of the thermal, mechanical, rheological, and metallization performance of the blend compositions. Exemplary high heat polycarbonates for inclusion in the blend compositions include polycarbonates derived from 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine (PPPBP). The polycarbonate can be derived from PPPBP and Bisphenol A (BPA). The PPPBP-BPA copolymer can be prepared by interfacial polymerization or by a melt process. The PPPBP-BPA copolymer can have endcaps derived from paracumyl phenol (PCP), for example.

The PPPBP-BPA copolymer can include 1 to 50 mol % PPPBP, 10 to 45 mol % PPPBP, 15 to 40 nmol % PPPBP, 20 to 35 mol % PPPBP, 25 to 40 mol % PPPBP, 25 to 35 mol % PPPBP, 30 to 35 mol % PPPBP, or 32 to 33 mol % PPPBP. The PPPBP-BPA copolymer can include 1 mol %, 2 mol %, 3 mol %, 4 mol %, 5 mol %, 6 mol %, 7 mol %, 8 mol %, 9 mol %, 10 mol %, 11 mol %, 12 mol %, 13 mol %, 14 mol %, 15 mol %, 16 mol %, 17 mol %, 18 mol %, 19 mol %, 20 mol %, 21 mol %, 22 mol %, 23 mol %, 24 mol %, 25 mol %, 26 mol %, 27 mol %, 28 mol %, 29 mol %, 30 mol %, 31 mol %, 32 mol %, 33 mol %, 34 mol %, 35 mol %, 36 mol %, 37 mol %, 38 mol %, 39 mol %, 40 mol %, 41 mol %, 42 mol %, 43 mol %, 44 mol %, 45 mol %, 46 mol %, 47 mol %, 48 mol %, 49 mol %, or 50 mol % PPPBP. The PPPBP-BPA copolymer can include 18 mol % PPPBP. The PPPBP-BPA copolymer can include 32 mol % PPPBP.

The PPPBP-BPA copolymer can have a weight average molecular weight of 15,500 to 40,000 g/mol, 16,000 to 35,000 g/mol, 17,000 to 30,000 g/mol, 15,500 to 25,000 g/mol, 15,500 to 23,000 g/mol, 17,000 to 23,000 g/mol, or 17,000 to 20.000 g/mol. The PPPBP-BPA copolymer, optionally having paracumyl phenol derived endcaps, can have a weight average molecular weight of 15.500 g/mol, 16,000 g/mol, 16,500 g/mol, 17,000 g/mol, 17,500 g/mol, 18,000 g/mol, 18,500 g/mol, 19,000 g/mol, 19,500 g/mol, 20,000 g/mol, 20,500 g/mol, 21,000 g/mol, 21,500 g/mol, 22,000 g/mol, 22,500 g/mol, 23,000 g/mol, 23,500 g/mol, 24,000 g/mol, 24,500 g/mol, 25,000 g/mol, 25,500 g/mol, 26,000 g/mol, 26,500 g/mol, 27,000 g/mol, 27,500 g/mol, 28,000 g/mol, 28,500 g/mol, 29,000 g/mol, 29,500 g/mol, or 30,000 g/mol. The PPPBP-BPA copolymer can have a weight average molecular weight of 17,000 g/mol, 20,000 g/mol, or 23,000 g/mol. The PPPBP-BPA copolymer can have a weight average molecular weight of 17,300 g/mol, 19,900 g/mol, or 23,000 g/mol. Weight average molecular weight can be determined by GPC using BPA polycarbonate standards.

The PPPBP-BPA copolymers can have a polydispersity index (PDI) of 1.0 to 10.0, 2.0 to 7.0, or 2.0 to 3.0. In certain embodiments, the PPPBP-BPA copolymer have a PDI of 1.00, 1.50, 2.00, 2.50, 3.00, 3.50, 4.00, 4.50, 5.00, 5.50, 6.00, 6.50, 7.00, or 7.50. In certain embodiments, the PPPBP-BPA copolymers have a PDI of 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3.0. In certain embodiments, the PPPBP-BPA copolymers have a PDI of 2.2 or 2.3.

The PPPBP-BPA copolymer can have a Tg of greater than or equal to 150° C., greater than or equal to 155° C., greater than or equal to 160° C., greater than or equal to 165° C., greater than or equal to 170° C., greater than or equal to 175° C., greater than or equal to 180° C., greater than or equal to 185° C., greater than or equal to 190° C., greater than or equal to 200° C., greater than or equal to 210° C., greater than or equal to 220° C., greater than or equal to 230° C., greater than or equal to 240° C., greater than or equal to 250° C., greater than or equal to 260° C., greater than or equal to 270° C., greater than or equal to 280° C., greater than or equal to 290° C., or greater than or equal to 300° C., as measured using a differential scanning calorimetry method.

The PPPBP-BPA copolymer can be present in the blend compositions in an amount ranging from 30 to 95 wt %, 35 to 95 wt %, 40 to 95 wt %, 45 to 95 wt %, 50 to 95 wt %, 55 to 95 wt %, 60 to 95 wt %, 60 to 90 wt %, 60 to 85 wt %, or 60 to 80 wt %, based on total weight of the composition. The PPPBP-BPA copolymer can be present in the blend compositions in an amount of 40 wt %, 41 wt %, 42 wt %, 43 wt %, 44 wt %, 45 wt %, 46 wt %, 47 wt %, 48 wt %, 49 wt %, 50 wt %, 51 wt %, 52 wt %, 53 wt %, 54 wt %, 55 wt %, 56 wt %, 57 wt %, 58 wt %, 59 wt %, 60 wt %, 61 wt %, 62 wt %, 63 wt %, 64 wt %, 65 wt %, 66 wt %, 67 wt %, 68 wt %, 69 wt %, 70 wt %, 71 wt %, 72 wt %, 73 wt %, 74 wt %, 75 wt %, 76 wt %, 77 wt %, 78 wt %, 79 wt %, 80 wt %, 81 wt %, 82 wt %, 83 wt %, 84 wt %, 85 wt %, 86 wt %, 87 wt %, 88 wt %, 89 wt %, or 90 wt %, based on total weight of the composition.

In certain embodiments, the blend compositions include a PPPBP-BPA copolymer selected from the group consisting of: a PCP end-capped linear PPPBP-BPA copolymer having a weight average molecular weight of 23,000 g/mol [^(±)1,000 g/mol]; a PCP end-capped linear PPPBP-BPA copolymer having a weight average molecular weight of 20,000 g/mol [^(±)1,000 g/mol]; and a PCP end-capped linear PPPBP-BPA copolymer having a weight average molecular weight of 17,000 g/mol [^(±)1,000 g/mol]; or any combination thereof; wherein the weight average molecular weight is as determined by GPC using BPA polycarbonate standards. In certain embodiments, the PPPBP-BPA copolymers include 31 to 35 mol % PPPBP content, or 32 to 33 mol % PPPBP content.

The polycarbonate blend compositions can include one or more polycarbonates to enhance one or more of the thermal, mechanical, rheological, and metallization performance of the blend compositions. Exemplary polycarbonates for inclusion in the blend compositions include homopolycarbonates derived from Bisphenol A. The BPA polycarbonate can be prepared by interfacial polymerization or by a melt process. The BPA polycarbonate can have endcaps derived from phenol, paracumyl phenol (PCP), or a combination thereof.

The BPA polycarbonate can have a weight average molecular weight of 17,000 to 40,000 g/mol, 17,000 to 35,000 g/mol, 17,000 to 30,000 g/mol, 17,000 to 25,000 g/mol, 17,000 to 23,000 g/mol, 17,000 to 22,000 g/mol, 18,000 to 22,000, 18,000 to 35,000 g/mol, 18,000 to 30,000 g/mol, 25,000 to 30,000 g/mol, 26,000 to 30,000 g/mol, 27,000 to 30,000 g/mol, 28,000 to 30,000 g/mol, or 29,000 to 30,000 g/mol. The BPA polycarbonate, optionally having phenol or paracumyl phenol derived endcaps, can have a weight average molecular weight of 17,000 g/mol, 17,500 g/mol, 18,000 g/mol, 18,500 g/mol, 19,000 g/mol, 19,500 g/mol, 20,000 g/mol, 20,500 g/mol, 21,000 g/mol, 21,500 g/mol, 22,000 g/mol, 22,500 g/mol, 23,000 g/mol, 23,500 g/mol, 24,000 g/mol, 24,500 g/mol, 25,000 g/mol, 25,500 g/mol, 26,000 g/mol, 26,500 g/mol, 27,000 g/mol, 27,500 g/mol, 28,000 g/mol, 28,500 g/mol, 29,000 g/mol, 29,500 g/mol, 30,000 g/mol, 30,500 g/mol, 31,000 g/mol, 31,500 g/mol, 32,000 g/mol, 32,500 g/mol, 33,000 g/mol, 33,500 g/mol, 34,000 g/mol, 34,500 g/mol, 35,000 g/mol, 35,500 g/mol, 36,000 g/mol, 36,500 g/mol, 37,000 g/mol, 37,500 g/mol, 38,000 g/mol, 38,500 g/mol, 39,000 g/mol, 39,500 g/mol, or 40,000 g/mol. The BPA polycarbonate can have a weight average molecular weight of 18,200 g/mol, 18,800 g/mol, 21,800 g/mol, 21,900 g/mol, 29,900 g/mol, or 30,000 g/mol. Weight average molecular weight can be determined by GPC using BPA polycarbonate standards.

The BPA polycarbonates can have a polydispersity index (PDI) of 1.0 to 10.0, 2.0 to 7.0, or 2.0 to 3.0. In certain embodiments, the BPA polycarbonates have a PDI of 1.00, 1.50, 2.00, 2.50, 3.00, 3.50, 4.00, 4.50, 5.00, 5.50, 6.00, 6.50, 7.00, or 7.50. In certain embodiments, the BPA polycarbonates can have a PDI of 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3.0. In certain embodiments, the BPA polycarbonates have a PDI of 2.2 or 2.3.

The BPA polycarbonate can be present in the blend compositions in an amount ranging from 1 to 60 wt %, 3 to 55 wt %, 5 to 50 wt %, or 10 to 35 wt %, based on total weight of the composition. The BPA polycarbonate can be present in the blend compositions in an amount of 1 wt %, 2 wt %, 3 wt %, 4 wt %, 5 wt %, 6 wt %, 7 wt %, 8 wt %, 9 wt %, 10 wt %, 11 wt %, 12 wt %, 13 wt %, 14 wt %, 15 wt %, 16 wt %, 17 wt %, 18 wt %, 19 wt %, 20 wt %, 21 wt %, 22 wt %, 23 wt %, 24 wt %, 25 wt %, 26 wt %, 27 wt %, 28 wt %, 29 wt %, 30 wt %, 31 wt %, 32 wt %, 33 wt %, 34 wt %, 35 wt %, 36 wt %, 37 wt %, 38 wt %, 39 wt %, 40 wt %, 41 wt %, 42 wt %, 43 wt %, 44 wt %, 45 wt %, 46 wt %, 47 wt %, 48 wt %, 49 wt %, 50 wt %, 51 wt %, 52 wt %, 53 wt %, 54 wt %, 55 wt %, 56 wt %, 57 wt %, 58 wt %, 59 wt %, or 60 wt %, based on total weight of the composition.

In certain embodiments, the blend compositions include a BPA polycarbonate selected from the group consisting of: a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 18,200 g/mol [^(±)1,000 g/mol]; a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 18,800 g/mol [^(±)1,000 g/mol]; a phenol end-capped linear BPA polycarbonate having a weight average molecular weight of 21,800 g/mol [^(±)1,000 g/mol]; a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 21,900 g/mol [^(±)1,000 g/mol]; a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 29,900 g/mol [^(±)1,000 g/mol]; and a phenol end-capped linear BPA polycarbonate having a weight average molecular weight of 30,000 g/mol [^(±)1,000 g/mol]; or any combination thereof; wherein the weight average molecular weight is as determined by GPC using BPA polycarbonate standards.

The polycarbonate blend compositions can include one or more polyester-polycarbonate copolymer to enhance one or more of the thermal, mechanical, rheological, and metallization performance of the blend compositions. Exemplary polyester-polycarbonate copolymer for inclusion in the blend compositions include polycarbonates comprising aliphatic dicarboxylic acid units, and more specifically, polycarbonates including aliphatic dicarboxylic acids units and units derived from BPA. The polyester-polycarbonate copolymers can be prepared by interfacial polymerization. The polyester-polycarbonate copolymers can be prepared via a continuous flow reactor (e.g., a tube reactor). The polyester-polycarbonate copolymers can have endcaps derived from paracumyl phenol (PCP), for example.

The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can include 1 to 25 mol % aliphatic dicarboxylic acid content, 0.5 to 10 mol % aliphatic dicarboxylic acid content, 1 to 9 mol % aliphatic dicarboxylic acid content, or 3 to 8 mol % aliphatic dicarboxylic acid content. The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can include 1 mol %, 2 mol %, 3 mol %, 4 mol %, 5 mol %, 6 mol %, 7 mol %, 8 mol %, 9 mol %, 10 mol %, 11 mol %, 12 mol %, 13 mol %, 14 mol %, 15 mol %, 16 mol %, 17 mol %, 18 mol %, 19 mol %, 20 mol %, 21 mol %, 22 mol %, 23 mol %, 24 mol %, or 25 mol % aliphatic dicarboxylic acid content. The polyester-polycarbonate copolymer can include 3 mol % aliphatic dicarboxylic acid content. The polyester-polycarbonate copolymer can include 4 mol % aliphatic dicarboxylic acid content. The polyester-polycarbonate copolymer can include 5 mol % aliphatic dicarboxylic acid content. The polyester-polycarbonate copolymer can include 6 mol % aliphatic dicarboxylic acid content. The polyester-polycarbonate copolymer can include 7 mol % aliphatic dicarboxylic acid content. The polyester-polycarbonate copolymer can include 8 mol % aliphatic dicarboxylic acid content.

The poly(aliphatic ester)-polycarbonate copolymer, can include 1 to 25 mol % sebacic acid content, 0.5 to 10 mol % sebacic acid content, 1 to 9 mol % sebacic acid content, or 3 to 8 mol % sebacic acid content. The poly(aliphatic ester)-polycarbonate copolymer, can include 1 mol %, 2 mol %, 3 mol %, 4 mol %, 5 mol %, 6 mol %, 7 mol %, 8 mol %, 9 mol %, 10 mol %, 11 mol %, 12 mol %, 13 mol %, 14 mol %, 15 mol %, 16 mol %, 17 mol %, 18 mol %, 19 mol %, 20 mol %, 21 mol %, 22 mol %, 23 mol %, 24 mol %, or 25 mol % sebacic acid content. The poly(aliphatic ester)-polycarbonate copolymer can include 3 mol % sebacic acid content. The poly(aliphatic ester)-polycarbonate copolymer can include 4 mol % sebacic acid content. The poly(aliphatic ester)-polycarbonate copolymer can include 5 mol % sebacic acid content. The poly(aliphatic ester)-polycarbonate copolymer can include 6 mol % sebacic acid content. The poly(aliphatic ester)-polycarbonate copolymer can include 7 mol % sebacic acid content. The poly(aliphatic ester)-polycarbonate copolymer can include 8 mol % sebacic acid content.

The poly(aliphatic ester)-polycarbonate copolymer can have from 4.0 to 12.0 mol % of sebacic acid (of the total composition). The poly(aliphatic ester)-polycarbonate copolymer can have from 5.0 to 11.0 mol %, from 6.0 to 10.0 mol %, from 4.0 to 10.0 mol %, from 7.0 to 9.0 mol %, from 7.5 to 8.5 mol %, from 5.0 to 7.0 mol %, or from 5.5 to 6.5 mol % of sebacic acid (of the total composition). The poly(aliphatic ester)-polycarbonate copolymer can have 8.25 mol % of sebacic acid (of the total composition). The poly(aliphatic ester)-polycarbonate copolymer can have 6.0 mol % of sebacic acid (of the total composition).

The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer can have a weight average molecular weight of 1,500 to 100,000 g/mol, 1,700 to 50,000 g/mol, 15,000 to 45,000 g/mol, 17,000 to 40,000 g/mol, 15,000 to 25,000 g/mol, 15,000 to 23,000 g/mol, or 20,000 to 25,000 g/mol. The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer can have a weight average molecular weight of 15,000 g/mol, 16,000 g/mol, 17,000 g/mol, 18,000 g/mol, 19,000 g/mol, 20,000 g/mol, 21,000 g/mol, 22,000 g/mol, 23,000 g/mol, 24,000 g/mol, 25,000 g/mol, 26,000 g/mol, 27,000 g/mol, 28,000 g/mol, 29,000 g/mol, 30,000 g/mol, 31,000 g/mol, 32,000 g/mol, 33,000 g/mol, 34,000 g/mol, 35,000 g/mol, 36,000 g/mol, 37,000 g/mol, 38,000 g/mol, 39,000 g/mol, or 40,000 g/mol. Weight average molecular weight can be determined by GPC using BPA polycarbonate standards.

The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can be present in the blend compositions in an amount ranging from 1 to 40 wt %, 5 to 35 wt %, or 10 to 35 wt %, based on total weight of the composition. The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can be present in the blend compositions in an amount of 1 wt %, 2 wt %, 3 wt %, 4 wt %, 5 wt %, 6 wt %, 7 wt %, 8 wt %, 9 wt %, 10 wt %, 11 wt %, 12 wt %, 13 wt %, 14 wt %, 15 wt %, 16 wt %, 17 wt %, 18 wt %, 19 wt %, 20 wt %, 21 wt %, 22 wt %, 23 wt %, 24 wt %, 25 wt %, 26 wt %, 27 wt %, 28 wt %, 29 wt %, 30 wt %, 31 wt %, 32 wt %, 33 wt %, 34 wt %, 35 wt %, 36 wt %, 37 wt %, 38 wt %, 39 wt %, or 40 wt %, based on total weight of the composition.

The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can have an MVR of 5 to 150 ml/10 min. 7 to 125 ml/10 min, 9 to 110 ml/10 min, or 10 to 100 ml/10 min, measured at 300° C., and a load of 1.2 kilograms according to ASTM D1238-04 or ISO 1133.

The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can have an MFR of 20 to 110 g/10 min, 45 to 100 g/10, 45 to 60 g/10 min. 85 to 110 g/10 min, or at least 85 g/10 min. The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can have an MFR of 45 g/10 min, 50 g/10 min, 55 g/10 min. 60 g/10 min, 65 g/10 min, 70 g/10 min, 75 g/10 min, 80 g/10 min, 85 g/10 min, 90 g/10 min. 95 g/10 min, 100 g/10 min. 105 g/10 min, 110 g/10 min, 115 g/10 min. or 120 g/10 min, measured according to ASTM D1238.

The polyester-polycarbonate copolymer, such as a poly(aliphatic ester)-polycarbonate copolymer, can have a biocontent according to ASTM-D-6866 of at least 2 wt %, at least 3 wt %, at least 4 wt %, at least 5 wt %, at least 6 wt %, at least 7 wt %, at least 8 wt %, at least 9 wt %, at least 10 wt %, at least 11 wt %, at least 12 wt %, at least 13 wt %, at least 14 wt %, at least 15 wt %, at least 16 wt %, at least 17 wt %, at least 18 wt %, at least 19 wt %, at least 20 wt %, at least 25 wt %, at least 30 wt %, at least 35 wt %, at least 40 wt %, at least 45 wt %, at least 50 wt %, at least 55 wt %, at least 60 wt %, or at least 65 wt % of the composition derived therefrom.

In certain embodiments, the blend compositions include a polyester-polycarbonate copolymer selected from the group consisting of: a PCP end-capped BPA polycarbonate-poly(aliphatic ester) copolymer comprising 6 mol % sebacic acid, and having a weight average molecular weight of 18,000 g/mol [^(±)1,000 g/mol], and a melt flow rate of at least 85 g/10 min. measured according to ASTM D1238 (300° C., 1.2 kgf); and a PCP end-capped BPA polycarbonate-poly(aliphatic ester) copolymer comprising 6 mole % sebacic acid, and having a weight average molecular weight of 22,000 g/mol [^(±)1,000 g/mol], and a melt flow rate of 45 g/10 min to 60 g/10 min, measured according to ASTM D1238 (300° C., 1.2 kgf); or a combination thereof; wherein the weight average molecular weight is as determined by GPC using BPA polycarbonate standards.

The polycarbonate blend compositions can include one or more additives. Exemplary additives for inclusion in the blend compositions include, for example, pentacrythritol tetrastearate (PETS), pentaerythrithol tetrakis-(3-dodecylthiopropionate) (SEENOX 412S), tetrakis(2,4-di-tert-butylphenyl)[1,1-biphenyl]-4,4′-diylbisphosphonite (PEPQ), monozinc phosphate (MZP), phosphoric acid, hydroxyl octaphenyl benzotriazole, and any combination thereof.

In certain embodiments, the blend compositions include PETS, a phosphite stabilizer (e.g., Iragafos 168), and a hindered phenol (e.g., Irgafos 1076). In certain embodiments, the blend compositions include 0.27 wt % PETS, 0.08 wt % phosphite stabilizer (e.g., Iragafos 168), and 0.04 wt % hindered phenol (e.g., Irgafos 1076), based on total weight of the composition.

EXAMPLES

Physical testing (e.g., heat deflection temperature, melt volume flow rate, melt flow rate, melt viscosity, melt stability, multiaxial impact) is performed according to ISO or ASTM standards. Unless indicated otherwise, all test standards refer to those in effect in 2014.

Heat deflection temperature (HDT) is a relative measure of a material's ability to perform for a short time at elevated temperatures while supporting a load. The test measures the effect of temperature on stiffness: a standard test specimen is given a defined surface stress and the temperature is raised at a uniform rate. HDT is determined as flatwise under 1.82 MPa or 0.45 MPa loading with 3.2 mm (4 mm for ISO) thickness bar according to ASTM D648-2007 or ISO75-2013. Results are reported in ° C.

Melt volume rate (MVR) is measured at 300° C./2.16 kg or 330° C./2.16 kg as per ASTM D 1238-2010 or ISO1133-2011. Melt viscosity (MV) is measured according to ASTM-D3835-2008 or ISO11443-2005 at a temperature of 300° C. or 316° C. and shear rate of 1500 or 5000 s⁻¹.

Multiaxial impact is measured according to ASTM D3763-2010 or ISO 6603-2000. Notched izod impact is measured according to ASTM D256-2010 or ISO 180-2000. Tensile modulus is measured according to ASTM D638-2010.

Differential scanning calorimetry (DSC) employing a temperature sweep rate of 20° C./min is used to determine Tgs.

Flammability tests can be performed following the procedure of Underwriter's Laboratory Bulletin 94 entitled “rests for Flammability of Plastic Materials, UL94.” According to this procedure, materials can be classified as V-0, V-1 or V-2 on the basis of the test results obtained for samples of 3.0 millimeter thickness. The samples are made according to the UL94 test procedure using standard ASTM molding criteria. Samples are burned in a vertical orientation after aging for 48 hours at 23° C., 50% relative humidity or 168 hours at 70° C. At least 10 injection molded bars are burned for each UL test.

Molecular weight determinations are performed using GPC, using a cross-linked styrene-divinylbenzene column and calibrated to bisphenol-A polycarbonate standards using a UV-VIS detector set at 254 nm. Samples are prepared at a concentration of 1 mg/nil, and eluted at a flow rate of 1.0 ml/min.

Table 1 summarizes the exemplary materials components of the polycarbonate blend compositions. The listed copolymers and polycarbonate resins were prepared by methods known in the art. All other chemical entities were purchased from the commercial sources listed.

TABLE 1 PPPBP-PC-1 PPPBP (N-Phenylphenolphthalein- SABIC ylbisphenol, 2,2-Bis(4-hydro) - Bisphenol A Copolymer, 32 mol % PPPBP, Mw 23,000 g/mol, interfacial polymerization, PCP end- capped, PDI = 2-3 PC-5 Linear Bisphenol A polycarbonate produced SABIC by interfacial polymerization, Mw 21,900 g/mol as determined by GPC using polycarbonate standards, PCP end-capped, PDI = 2-3 PE-PC-1 Poly(aliphatic ester) - Bisphenol A SABIC polycarbonate copolymer, 6 mole % sebacic acid, Mw 18,000 g/mol as determined by GPC using polycarbonate standards, para- cumylphenol (PCP) end-capped, having a melt flow rate of 100 g/10 min measured according to ASTM D1238 (300° C., 1.2 kgf). PE-PC-2 Poly(aliphatic ester) - Bisphenol A SABIC polycarbonate copolymer, 6 mole % sebacic acid, Mw 22,000 g/mol as determined by GPC using polycarbonate standards, para- cumylphenol (PCP) end-capped, having a melt flow rate of 55 g/10 min measured according to ASTM D1238 (300° C., 1.2 kgf). PETS Pentaerythritol Tetrastearate LONZA Phosphite Tris(di-t-butylphenyl)phosphite BASF stabilizer Hindered Octadecyl 3-(3,5-di-tert-butyl-4- BASF Phenol hydroxyphenyl)propionate BPA 4,4′-(propane-2,2-diyl)diphenol SABIC BPADP Bisphenol A diphosphate KSS Potassium diphenylsulfone sulfonate Rimar-K Potassium perfluorobutane sulfonate FYROLFLE oligomeric phosphate ester; Phosphorus ICL IND. X ™ Sol-DP Content: 10.7%; Specific Gravity: 1.3; PRODUCTS Melting Range: 101-108° C. TSAN Styrene-Acrylonitrile copolymer encapsulated PTFE General Sebacic Acid Copolyestercarbonate Resin Synthesis Description

Bisphenol-A and sebacic acid are weighed, then transferred to a formulation tank which contains methylene chloride, water, triethyamine (catalyst) and a small amount of aqueous sodium hydroxide. The mixture is agitated for 5 minutes and then transferred to the polymerization reactor. Phosgene is added to the reaction mixture over the course of 25 minutes. P-cumylphenol is added to the polymerization reactor over the course of five minutes during the phosgenation. Aqueous sodium hydroxide is additionally added in order to control reaction pH.

Alternatively, sebacic acid is dissolved in a mixture of water and aqueous sodium hydroxide. Bisphenol-A is weighed, then transferred to a formulation tank which contains methylene chloride, water and triethylamine (catalyst). The formulation mixture is transferred to the polymerization reactor. The sebacic acid solution is transferred to the polymerization reactor. Phosgene is added to the reaction mixture over the course of 25 minutes. P-cumylphenol is added to the reactor over the course of five minutes during the phosgenation. Aqueous sodium hydroxide is additionally added in order to control reaction pH.

After completion of the polymerization, the reaction mixture is discharged to the centrifuge feed tank. The polymer solution is purified by feeding the reaction product to a train of liquid/liquid centrifuges. The first centrifuge stage separates the reaction by product brine from the resin solution. The second centrifuge stage removes catalyst from the resin solution by washing with dilute aqueous hydrochloric acid. The third centrifuge stage removes residual ionic species by washing the resin solution with water.

The purified resin solution is then concentrated by evaporation of methylene chloride. The resin is then precipitated by co-feeding the resin solution to a jet with steam to flash off the methylene chloride. Residual methylene chloride is removed from the resin by counter current contact with steam. Excess water is removed from the resin using heated air in a fluidizing dryer.

Procedures as disclosed in U.S. Patent Application Publication No. 2013/0196131 can be employed for the synthesis of the poly(aliphatic ester)-bisphenol A polycarbonate copolymers described and used herein.

Specific Sebacic Acid Copolyestercarbonate Resin Synthesis Process Description

In a Nalgene plastic container is placed sebacic acid (242 g, 1.19 moles), 50% NaOH (280 g, 3.5 moles), and water (2500 mL) (referred to as the “sebacic acid solution”). The mixture is placed on a platform shaker and mixed until dissolved. To a formulation tank is added dichloromethane (10 L), deionized water (10 L), bisphenol-A (4268 g, 18.71 moles), the sebacic acid solution, para-cumyl phenol (163 g, 0.77 moles), triethylamine (50 g, 0.49 moles, 2.5 mol %), and sodium gluconate (10 g). The mixture is stirred and transferred to a batch reactor. The reactor agitator is started and the circulation flow is set at 80 L/min. Phosgene vapor flow to the reactor is initiated by the distributed control system (DCS) in three continuous segments separated by different pH targets. Reaction pH is controlled by DCS addition of 50% aqueous NaOH. During segment 1 (50% of total phosgene charge, 1295 g, 13.1 moles) the reaction pH target is 7.25. During segment 2 (phosgene charge 320 g, 3.2 moles) the reaction pH target is ramped from 7.25 to 10.2. Segment 3 (phosgene 965 g, 9.7 moles) maintains a pH target of 10.2 until the total phosgene setpoint is reached (2580 g, 26.0 moles). A sample of the reactor is obtained and verified to be free of unreacted BPA and free of chloroformate. Mw of the reaction sample is determined by GPC (21,500 g/mol). The reactor is purged with nitrogen and the batch is transferred to centrifuges for HCl/water wash and isolation via steam precipitation, as described above.

PE-PC-1 and PE-PC-2 Manufacture

PE-PC-1 is prepared using reactive chain-chopping chemistry with a redistribution catalyst during extrusion. The poly(aliphatic ester)-bisphenol A polycarbonate copolymer prepared in the procedure above, is mixed one or more additional components (e.g., a mold release agent (PETS), a heat stabilizer (Irgaphos)). This mixture is subjected to reactive chain chopping extrusion with a redistribution catalyst. The mixture is added to a 30 mm co-rotating twin screw (Werner & Pfleiderer; ZSK-30) extruder using a melt temperature of 300° C. with a rate of 20 kgs/hr, 20 inches of mercury vacuum and a screw speed of 400 RPM. A redistribution catalyst (tetrabutyl phosphonium hydroxide, 45% solution in water) is fed into the extruder using a separate liquid pump feeder. The extrudate is cooled under water and pelletized and dried at 120° C. for 4 hours with a desiccant bed dryer to afford PE-PC-1 (100 g/10 minutes melt flow rate at 300° C. under 1.2 kgf).

“PE-PC-2” refers to a high flow ductile thermoplastic resin having a 55 g/10 minutes melt flow rate at 300° C. under 1.2 kgf. The PE-PC-2 can be derived from a higher weight average molecular weight poly(aliphatic ester)-bisphenol A polycarbonate copolymer than that used to produce PE-PC-1. The PE-PC-2 can be prepared in a process analogous to that described for PE-PC-1 above.

Compositions comprising the thermoplastic composition can be manufactured by various methods. For example, the poly(aliphatic ester)-polycarbonate copolymer, a redistribution catalyst, and additional components can be first blended in a high speed HENSCHEL-Mixer. Other low shear processes, including but not limited to hand mixing, can also accomplish this blending. The blend can then be fed into the throat of a single or twin-screw extruder via a hopper. Alternatively, at least one of the components can be incorporated into the composition by feeding directly into the extruder at the throat or downstream through a sidestuffer. Additives can also be compounded into a masterbatch with a desired polymeric resin and fed into the extruder. The extruder is generally operated at a temperature higher than that necessary to cause the composition to flow. The extrudate is immediately quenched in a water batch and pelletized. The pellets, so prepared, when cutting the extrudate can be one-fourth inch long or less as desired. Such pellets can be used for subsequent molding, shaping, or forming.

Unless stated otherwise, the phrase “0.4 wt % additives,” “0.39 wt % additives,” or a derivation thereof, as used in the following tables, refers to 0.27 wt % pentaerythritol tetrastearate (PETS)+0.08 wt % phosphite stabilizer (e.g., Iragafos 168)+0.04 wt % hindered phenol (e.g., Irgafos 1076).

Compositions with Polyester-Polycarbonate Copolymers

Polyester-polycarbonate copolymers were incorporated into polycarbonate blend compositions to improve flow, while maintaining good heat performance, and flame retardance.

Compositions were prepared incorporating a variety of flame retardant agents into the compositions. Table 5 reveals that the addition of transparent flame retardant materials such as Rimar, KSS, BPADP or SolDP resulted in good flow properties, but a decrease in heat properties. Compositions that included TSAN (3, 6, 9) provided good flame retardant properties at 3 mm thickness. However, these three compositions lost transparency with the addition of TSAN.

TABLE 5 Composition 1 2 3 4 5 6 7 8 9 PPPBP-PC-1 (%) 65 65 65 65 65 65 65 65 65 PC-5 (%) 9.61 9.23 9.03 3.61 4.47 1.37 1.37 PE-PC-1 (%) 25.0 25 25 25 25.0 24.8 25 25 24.8 PETS (%) 0.75 0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27 Phosphite Stab.; 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 Irgafos 168 (%) Hindered Phenol; 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 Irgafos 1076 (%) Rimar-K (%) 0.08 0.08 KSS (%) 0.30 0.30 TSAN (%) 0.2 0.2 0.2 BPADP (%) 6 9.61 9.61 FyrolflexSolDP (%) 5.14 8.24 8.24 HDT, 0.45 MPa, 163 162 161 136 130 129 145 130 130 3.2 mm (° C.) Melt, vis 316° C., 130 113 114 83 62 65 83 72 71 5000 s⁻¹ (Pa-s) MFR; 330° C.; 2.16 kg, 41 55 57 84 122 126 92 104 108 360 s (g/10 mm) MVR; 330° C.; 2.16 kg, 38 52 50 78 110 114 82 96 38 360 s (mL/10 min) MAI Total Energy, 63 58 59 62 49 51 61 61 65 23° C. (J) Ductility (%) 80 40 40 50 40 40 50 100 80 Tensile Modulus, 2678 2760 2744 3044 3198 3132 2898 3098 3106 23° C. (Mpa) Elongation at break, 71 72 29 45 22 40 60 47 25 23° C. (%) Flame class - 3 mm V-2 V-2 V-0 none V-2 V-0 V-2 V-2 V-0 Total flame time 176 83 61 x 161 37 240 169 19 (t1 + t2); 23° C., 48 hr (sec) Total flame time 303 108 45 223 193 9 193 125 7 (t1 + t2); 70° C., 168 hr (sec) Flame class - 2.5 V-2 — V-2 V-2 — V-2 — — V-0 mm Total flame time 210 — 99 190 — 22 — — 55 (t1 + t2); 23° C., 48 hr (sec) Total flame time 261 — 94 287 — 5 — — 33 (t1 + t2); 70° C., 168 hr (sec) Flame class - 1.5 none V-2 V-2 V-2 V-2 V-2 V-2 V-2 V-2 mm Total flame time 339 147 120 135 97 21 138 45 35 (t1 + t2); 23° C., 48 hr (sec) Total flame time — 141 232 180 80 52 67 18 71 (t1 + t2); 70° C., 168 hr (sec)

In an attempt to obtain compositions with high modulus properties, glass fibers were incorporated into the compositions (Table 6). Incorporation of glass fibers resulted in increased heat properties (HDT) and increased modulus, but decreased flow.

TABLE 6 Composition 1 10 11 12 13 14 15 PPPBP-PC-1 (%) 65 58.48 51.96 45.42 58.48 51.96 45.42 PC-5 (%) 9.61 8.64 7.67 6.72 8.64 7.67 6.72 PE-PC-1 (%) 25.0 22.49 19.98 17.47 22.49 19.98 17.47 PETS (%) 0.75 0.27 0.27 0.27 0.27 0.27 0.27 Phosphite Stab.; 0.08 0.08 0.08 0.08 0.08 0.08 0.08 Irgafos 168 (%) Hindered Phenol; 0.04 0.04 0.04 0.04 0.04 0.04 0.04 Irgafos 1076 (%) Bonding fiberglass 10 20 30 for Lexan (%) Standard 10 micron 10 20 30 PBT glass fiber (%) GPC Mol. Weight (Da) 22883 22532 22268 21773 22402 22416 22362 Ash (%) 0 10.4 22.9 31.75 9.84 20.14 33.05 HDT, 1.8 MPa (° C.) 150 161 165 165 164 165 165 MVR; 330° C.; 2.16 kg, 38 32 31 23 32 28 20 360 s (mL/10 min) MVR; 330° C.; 2.16 kg, 13 11 8 8 9 7 7 360 s (mL/10 min) Tensile Modulus, 2396 4010 6104 9218 4244 6756 9270 23° C. (Mpa) Elongation at break, 52.1 6.8 4.4 3.0 6.4 3.3 3.3 23° C. (%) Flex Modulus, 2640 3810 5920 8710 3950 6360 8720 23° C. (Mpa)

Compositions that combined glass fiber and flame retardant agents were prepared (Table 7). These compositions maintained good heat and flow properties, while also possessing excellent robust flame retardant properties, even at 1.0 mm thickness. In addition, these compositions unexpectedly possessed high impact strength (NII, compositions 17, 21, 22, 24, 25).

TABLE 7 Composition 1 16 17 18 19 20 21 22 23 24 25 PPPBP-PC-1 65 65 58.48 65.00 65.00 65.00 57.48 50.45 65.00 57.48 50.45 PC-5 (%) 9.61 9.03 7.76 24.50 1.37 1.37 1.37 PE-PC-1 (%) 25.0 24.70 22.49 24.50 24.30 22.02 19.05 24.50 22.02 19.05 PETS (%) 0.75 0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27 Phosphite Stab; 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 0.08 Irgafos 168 (%) Hindered Phenol; 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 0.04 Irgafos 1076 (%) Rimar-K (%) 0.08 0.08 KSS (%) 0.30 0.30 TSAN (%) 0.5 0.5 0.50 0.50 0.70 0.50 0.50 0.50 0.50 0.50 BPADP (%) 9.61 9.61 9.61 9.61 9.61 FyrolflexSolDP (%) 8.24 8.24 8.24 Standard 10 micron 10 10 20 10 20 PBT glass fiber (%) Tg - DSC (° C.) 170 170 171 137 138 136 134 133 138 134 132 HDT, 1.8 Mpa 161 — 168 129 128 128 133 130 130 134 132 (° C.) Melt, vis 316° C., 104 81 126 57 65 60 70 71 66 76 83 5000 s⁻¹ (Pa-s) MVR; 330° C.; 2.16 kg, 70 177 50 139 109 126 86 84 115 76 65 360 s (mL/10 min) Ash (%) 0.03 0.1 10.52 1.18 1.1 0 11.4 20.97 0.74 10.94 20.78 MAI Total Energy, 51 — 4 4 28 34 5 7 18 7 7 23° C. (J) NII, 23° C. (J/m) 34 — 40 16 19 14 26 43 19 29 54 Tensile Modulus, 2610 — 4126 2996 2956 2968 4556 7020 2888 4620 7066 23° C., 5 mm/min (MPa) Strength at break, 57 — 86 56 55 56 98 123 57 99 125 23° C. (MPa) Elongation at break, 23.84 — 6.19 13.96 17.34 25.84 3.61 2.58 53.65 4.12 2.55 23° C. (%) Tensile Modulus, 2578 — 4114 3000 2968 2982 4590 6930 2870 4592 7148 23° C., 50 mm/min (MPa) Strength at break, 57 — 91 70 59 59 99 128 57 105 122 23° C. (MPa) Elongation at break, 19.6 — 6.3 9.4 17.4 15.3 3.2 2.5 29.1 4.0 2.2 23° C. (%) Flame class - 2.5 V-2 V-1 V-1 V-0 V-0 V-0 V-0 V-0 V-0 V-0 — mm; 23° C., 48 hr V0 2.5 mm pFTP; 0 0.15 0.51 1.0 1.0 1.0 1.0 1.0 1.0 1.0 — 23° C., 48 hr V1 2.5 mm pFTP; 0 0.94 0.98 1.0 1.0 1.0 1.0 1.0 1.0 1.0 — 23° C., 48 hr Flame class - 2.5 V2 V0 V1 V0 V0 V0 V0 V0 V0 V0 V0 mm; 70° C., 168 hr V0 2.5 mm pFTP; 0.33 0.88 0.83 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 70° C., 168 hr V1 2.5 mm pFTP; 0.41 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 70° C., 168 hr Flame class - 1.5 V2 V2 — V2 V2 V2 V0 V0 V1 V0 V0 mm; 23° C., 48 hr V0 1.5 mm pFTP; 0 0 0 0 0 0 1.0 1.0 0.95 1.0 1.0 23° C., 48 hr V1 1.5 mm pFTP; 0 0 0.03 0 0 0 1.0 1.0 1.0 1.0 1.0 23° C., 48 hr Flame class - 1.5 V2 V2 V2 V0 V1 V0 V0 V0 V0 V0 V0 mm; 70° C., 168 hr V0 1.5 mm pFTP; 0 0 0 0.88 0.62 0.87 1.0 1.0 0.95 1.0 1.0 70° C., 168 hr V1 1.5 mm pFTP; 0 0 0.03 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 70° C., 168 hr Flame class - 1.0 V2 None V2 V0 V0 V2 V0 V0 V2 V0 V0 mm; 23° C., 48 hr V0 1.0 mm pFTP; 0 0 0 1.0 1.0 0.77 1.0 1.0 0.41 1.0 1.0 23° C., 48 hr V1 1.0 mm pFTP; 0 0 0 1.0 1.0 0.77 1.0 1.0 0.41 1.0 1.0 23° C., 48 hr Flame class - 1.0 V2 V2 V2 V2 V2 V2 V0 V0 V0 V0 V0 mm; 70° C., 168 hr V0 1.0 mm pFTP; 0 0 0 0.39 0.03 0.11 1.0 1.0 0.94 1.0 1.0 70° C., 168 hr V1 1.0 mm pFTP; 0 0 0.2 0.39 0.03 0.11 1.0 1.0 1.0 1.0 1.0 70° C., 168 hr

While the present invention is described in connection with what is presently considered to be the most practical and preferred embodiments, it should be appreciated that the invention is not limited to the disclosed embodiments, and is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the claims. Modifications and variations in the present invention can be made without departing from the novel aspects of the invention as defined in the claims. The appended claims should be construed broadly and in a manner consistent with the spirit and the scope of the invention herein.

For reasons of completeness, various aspects of the present disclosure are set out in the following numbered clauses:

Clause 1. An article comprising a thermoplastic composition comprising:

(a) a first polycarbonate that includes structural units derived from at least one of:

wherein R^(a) and R^(b) at each occurrence are each independently halogen, C₁-C₁₂ alkyl. C₁-C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; p and q at each occurrence are each independently 0 to 4; R¹³ at each occurrence is independently a halogen or a C₁-C₆ alkyl group; c at each occurrence is independently 0 to 4; R¹⁴ at each occurrence is independently a C₁-C₆ alkyl, phenyl, or phenyl substituted with up to five halogens or C₁-C₆ alkyl groups; R⁸ at each occurrence is independently C₁-C₁₂ alkyl or halogen, or two R⁸ groups together with the carbon atoms to which they are attached form a four-, five, or six-membered cycloalkyl group; and t is 0 to 10; (b) a poly(aliphatic ester)-polycarbonate copolymer of the formula:

wherein m is 4 to 18; x+y is 100; and R³ is formula (I) or formula (II) wherein R^(h) is halogen, alkyl, or haloalkyl; n is 0 to 4; and X^(a) is formula (III) or formula (IV) wherein R and R^(d) are each independently hydrogen, halogen, alkyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, or heteroarylalkyl; and R^(e) is a divalent alkyl group; and (c) optionally a second polycarbonate that is a Bisphenol A (BPA) polycarbonate having a weight average molecular weight of 17,000 to 40,000 g/mol, as determined by GPC using BPA polycarbonate standards; wherein the composition has a heat deflection temperature of at least 120° C., measured at 1.8 MPa in accordance with ASTM D 648; wherein the composition has a melt viscosity of less than 130 Pa·s, measured in accordance with ISO 11443 at 316° C. at a shear rate of 5000 s⁻¹.

Clause 2. The article of clause 1, further comprising a flame retardant.

Clause 3. The article of clause 1 or 2, further comprising glass fiber.

Clause 4. The article of any of clauses 1-3, further comprising TSAN.

Clause 5. The article of any of clauses 1-4, wherein a molded sample of the composition obtained under standard molding conditions has a notched izod impact energy of at least 20 J/m at 23° C., as measured in accordance with ASTM D 256.

Clause 6. The article of any one of clauses 1-5, wherein the composition has a tensile modulus measured at 5 mm/min of at least 3500 MPa or at least 4000 MPa, measured in accordance with ASTM D 638.

Clause 7. The article of any one of clauses 1-6, wherein the first polycarbonate comprises structural units derived from PPPBP, wherein the PPPBP content is at most 40 mol %, and wherein the first polycarbonate has a Tg of at least 170° C.

Clause 8. The article of any one of clauses 1-7, wherein the first polycarbonate comprises structural units derived from PPPBP, and has a weight average molecular weight of 15,500 to 40,000 g/mol, as determined by GPC using BPA polycarbonate standards.

Clause 9. The article of any one of clauses 1-8, wherein the first polycarbonate is selected from: a para-cumylphenol end-capped polycarbonate comprising structural units derived from PPPBP and BPA, having a weight average molecular weight of 20,000 g/mol as determined by GPC using BPA polycarbonate standards; and a para-cumylphenol end-capped polycarbonate comprising structural units derived from PPPBP and BPA, having a weight average molecular weight of 23,000 g/mol, as determined by GPC using BPA polycarbonate standards.

Clause 10. The article of any one of clauses 1-9, wherein the poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of 15,000 to 25,000 g/mol, as determined by GPC using BPA polycarbonate standards; wherein the poly(aliphatic ester)-polycarbonate copolymer has a Tg of at least 100° C.

Clause 11. The article of any one of clauses 1-10, wherein the poly(aliphatic ester)-polycarbonate copolymer has the formula:

wherein m is 8; and R³ is

Clause 12. The article of any one of clauses 1-11, wherein the poly(aliphatic ester)-polycarbonate copolymer is selected from a para-cumylphenol end-capped polyester-polycarbonate copolymer comprising structural units derived from sebacic acid and BPA, having a weight average molecular weight of 18,000 g/mol, as determined by GPC using BPA polycarbonate standards; and a melt flow rate of at least 85 g/10 min, measured according to ASTM D1238 (300° C., 1.2 kgf); and a para-cumylphenol end-capped polyester-polycarbonate copolymer comprising structural units derived from sebacic acid and BPA, having a weight average molecular weight of 22,000 g/mol, as determined by GPC using BPA polycarbonate standards; and a melt flow rate of 45 g/10 min to 60 g/10 min, measured according to ASTM D1238 (300° C., 1.2 kgf).

Clause 13. The article of any one of clauses 1-12, wherein the second polycarbonate is a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 18,200 g/mol, as determined by GPC using BPA polycarbonate standards; a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 18,800 g/mol, as determined by GPC using BPA polycarbonate standards; a phenol end-capped linear BPA polycarbonate having a weight average molecular weight of 21,800 g/mol as determined by GPC using BPA polycarbonate standards; a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 21,900 g/mol as determined by GPC using BPA polycarbonate standards; a PCP end-capped linear BPA polycarbonate having a weight average molecular weight of 29,900 g/mol as determined by GPC using BPA polycarbonate standards; or a phenol end-capped linear BPA polycarbonate having a weight average molecular weight of 30,000 g/mol as determined by GPC using BPA polycarbonate standards.

Clause 14. The article of any one of clauses 1-13, wherein the second polycarbonate is a BPA polycarbonate produced by interfacial or melt polymerization, having a weight average molecular weight of 29,900 g/mol as determined by GPC using BPA polycarbonate standards.

Clause 15. The article of any one of clauses 2-14, wherein the flame retardant is selected from at least one of potassium perfluorobutane sulfonate, potassium diphenylsulfone sulfonate and an organophosphorus compound.

Clause 16. The article of clause 15, wherein the organophosphorus compound is present in an amount effective to provide 0.1 to 1.5% of phosphorus, based on the weight of the composition.

Clause 17. The article of clause 15, wherein the organophosphorus compound is present in an amount effective to provide 0.6 to 1.2% of phosphorus, based on the weight of the composition.

Clause 18. The article of any one of clauses 15-17, wherein the organophosphorus compound is bisphenol A diphosphate, an oligomeric phosphate ester, or a combination thereof.

Clause 19. The article of any one of clauses 1-18, wherein the composition comprises 45 to 70 wt % of the first polycarbonate; 15 to 30 wt % of the poly(aliphatic ester)-polycarbonate copolymer; optionally 1 to 10 wt % of the second polycarbonate; optionally 0.05 to 10 wt % of the flame retardant; optionally 5 to 35 wt % of the glass fiber; optionally 0.1 to 2 wt % TSAN; provided that the combined wt % value of all components does not exceed 100 wt %.

Clause 20. The article according to any one of clauses 1-19, wherein the composition is selected from the group consisting of (1) to (7): (1) a composition comprising 65 wt % of the first polycarbonate; 24.70 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 9.03 wt % of the second polycarbonate; 0.38 wt % of the flame retardant; 0.50% TSAN and 0.39 wt % of additives; (2) a composition comprising 58.48 wt % of the first polycarbonate; 22.49 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 7.76 wt % of the second polycarbonate; 0.38 wt % of the flame retardant; 10.0% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (3) a composition comprising 65 wt % of the first polycarbonate; 24.5 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 9.61 wt % of the flame retardant; 0.50% TSAN and 0.39 wt % of additives; (4) a composition comprising 65 wt % of the first polycarbonate; 24.3 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 9.61 wt % of the flame retardant; 0.70% TSAN and 0.39 wt % of additives; (5) a composition comprising 57.48 wt % of the first polycarbonate; 22.02 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 9.61 wt % of the flame retardant; 10% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (6) a composition comprising 50.45 wt % of the first polycarbonate; 19.05 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 9.61 wt % of the flame retardant; 20% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (7) a composition comprising 65 wt % of the first polycarbonate; 24.5 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 1.37% of the second polycarbonate; 8.24 wt % of the flame retardant; 0.50% TSAN and 0.39 wt % of additives; (8) a composition comprising 57.48 wt % of the first polycarbonate; 22.02 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 1.37% of the second polycarbonate; 8.24 wt % of the flame retardant; 10% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (9) a composition comprising 50.45 wt % of the first polycarbonate; 19.05 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 1.37% of the second polycarbonate; 8.24 wt % of the flame retardant; 20% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives.

Clause 21. The article of any one of clauses 1-20, wherein a flame bar comprising the composition demonstrates a probability of first time pass (pFTP) of the UL1.94 V0 test of 1.0, tested at a thickness of 2.5 mm.

Clause 22. The article of any one of clauses 1-21, wherein a flame bar comprising the composition demonstrates a probability of first time pass (pFTP) of the UL94 V0 test of 1.0, tested at a thickness of 1.5 mm.

Clause 23. The article of any one of clauses 1-22, wherein a flame bar comprising the composition demonstrates a probability of first time pass (pFTP) of the UL94 V0 test of 1.0, tested at a thickness of 1.0 mm.

Clause 24. The article of any one of clauses 1-23, wherein a flame bar comprising the composition demonstrates a probability of first time pass (pFTP) of the UL94 V0 test of 1.0, tested at a thickness of 0.8 mm.

Clause 25. The article of any one of clauses 1-24, wherein the composition comprises 10 wt % to 30 wt % or 10 wt % to 20 wt % glass fiber and a notched izod impact energy of at least 20 J/m, at least 25 J/n, at least 30 J/m, at least 35 J/m, at least 40 J/m or at least 45 J/m at 23° C., as measured in accordance with ASTM D 256.

Clause 26. The article of any one of clauses 1-25, selected from electrical and electronic housings, electrical and electronic connectors, automotive connectors, light fixtures, light housings, instrument panels, interior trim, center consoles, panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, fascia, grilles, minor housings, pillar appliqués, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, circuit breakers, running boards, helmet or other protective device, fire helmets, and motor vehicle headlight covers, or any combination thereof. 

What is claimed is:
 1. An article comprising a thermoplastic composition comprising: (a) 45 to 70 wt % of a first polycarbonate that includes structural units derived from at least one of:

wherein R^(a) and R^(b) at each occurrence are each independently halogen, C₁-C₁₂ alkyl, C₁-C₁₂ alkenyl, C₃-C₈ cycloalkyl, or C₁-C₁₂ alkoxy; p and q at each occurrence are each independently 0 to 4; R¹³ at each occurrence is independently a halogen or a C₁-C₆ alkyl group; c at each occurrence is independently 0 to 4; R¹⁴ at each occurrence is independently a C₁-C₆ alkyl, phenyl, or phenyl substituted with up to five halogens or C₁-C₆, alkyl groups; R^(g) at each occurrence is independently C₁-C₁₂ alkyl or halogen, or two R^(g) groups together with the carbon atoms to which they are attached form a four-, five, or six-membered cycloalkyl group; and t is 1 to 10; (b) 15 to 30 wt % of a poly(aliphatic ester)-polycarbonate copolymer of the formula:

wherein m is 4 to 18; x, and y each represents parts by weight of the carbonate units and the ester units based on 100 parts total weight of the poly(aliphatic ester)-polycarbonate copolymer, x+y is 100; and R³ is formula (I) or formula (II):

wherein R^(h) is halogen, alkyl, or haloalkyl; n is 0 to 4; and X^(a) is formula (III) or formula (IV):

wherein R^(c) and R^(d) are each independently hydrogen, halogen, alkyl, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, or heteroarylalkyl; and R^(e) is a divalent alkyl group; and (c) optionally a second polycarbonate that is a Bisphenol A polycarbonate having a weight average molecular weight of 17,000 to 40,000 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; wherein the thermoplastic composition further comprises 0.05 to 10 wt % of a flame retardant and 5 to 35 wt % of glass fiber, provided that the combined wt % value of all components does not exceed 100 wt %, the composition has a heat deflection temperature of at least 120° C., measured at 1.8 MPa in accordance with ASTM D 648; and a melt viscosity of less than 130 Pa·s, measured in accordance with ISO 11443 at 316° C. at a shear rate of 5000 s⁻¹, and a molded sample of the composition obtained under standard molding conditions has a notched izod impact energy of at least 20 Jim at 23° C., as measured in accordance with ASTM D
 256. 2. The article of claim 1, further comprising TSAN.
 3. The article of claim 1, wherein the composition has a tensile modulus measured at 5 mm/min of at least 3500 MPa or at least 4000 MPa, measured in accordance with ASTM D
 638. 4. The article of claim 1, wherein the first polycarbonate comprises structural units derived from 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one, and has a weight average molecular weight of 15,500 to 40,000 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards.
 5. The article of claim 1, wherein the first polycarbonate is selected from: a para-cumylphenol end-capped polycarbonate comprising structural units derived from 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one and Bisphenol A, having a weight average molecular weight of 20,000 g/mol as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; and a para-cumylphenol end-capped polycarbonate comprising structural units derived from 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one and Bisphenol A, having a weight average molecular weight of 23,000 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards.
 6. The article of claim 1, wherein the poly(aliphatic ester)-polycarbonate copolymer has a weight average molecular weight of 15,000 to 25,000 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; wherein the poly(aliphatic ester)-polycarbonate copolymer has a Tg of at least 100° C.
 7. The article of claim 1, wherein the poly(aliphatic ester)-polycarbonate copolymer has the formula:

wherein m is 8; and R³ is


8. The article of claim 1, wherein the poly(aliphatic ester)-polycarbonate copolymer is selected from a para-cumylphenol end-capped polyester-polycarbonate copolymer comprising structural units derived from sebacic acid and Bisphenol A, having a weight average molecular weight of 18,000 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; and a melt flow rate of at least 85 g/10 min, measured according to ASTM D1238 at 300° C. and 1.2 kgf); and a para-cumylphenol end-capped polyester-polycarbonate copolymer comprising structural units derived from sebacic acid and Bisphenol A, having a weight average molecular weight of 22,000 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; and a melt flow rate of 45 g/10 min to 60 g/10 min, measured according to ASTM D1238 at 300° C. and 1.2 kgf).
 9. The article of claim 1, wherein the second polycarbonate is a para-cumylphenol end-capped linear Bisphenol A polycarbonate having a weight average molecular weight of 18,200 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; a para-cumylphenol end-capped linear Bisphenol A polycarbonate having a weight average molecular weight of 18,800 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; a phenol end-capped linear Bisphenol A polycarbonate having a weight average molecular weight of 21,800 g/mol as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; a para-cumylphenol end-capped linear Bisphenol A polycarbonate having a weight average molecular weight of 21,900 g/mol as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; a para-cumylphenol end-capped linear Bisphenol A polycarbonate having a weight average molecular weight of 29,900 g/mol as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; or a phenol end-capped linear Bisphenol A polycarbonate having a weight average molecular weight of 30,000 g/mol as determined by gel permeation chromatography using Bisphenol A polycarbonate standards.
 10. The article of claim 1, wherein the second polycarbonate is a Bisphenol A polycarbonate produced by interfacial or melt polymerization, having a weight average molecular weight of 29,900 g/mol as determined by gel permeation chromatography using Bisphenol A polycarbonate standards.
 11. The article of claim 1, wherein the flame retardant is selected from at least one of potassium perfluorobutane sulfonate, potassium diphenylsulfone sulfonate and an organophosphorus compound.
 12. The article of claim 11, wherein the organophosphorus compound is present in an amount effective to provide 0.1% to 1.5% of phosphorus, based on the weight of the composition.
 13. The article of claim 11, wherein the organophosphorus compound is bisphenol A diphosphate, an oligomeric phosphate ester, or a combination thereof.
 14. The article of claim 1, wherein the composition comprises 1 to 10 wt % of the second polycarbonate; optionally 0.1 to 2 wt % TSAN; provided that the combined wt % value of all components does not exceed 100 wt %.
 15. The article according to claim 1, wherein the composition is selected from the group consisting of (2), (5), (6), (8), and (9): (2) a composition comprising 58.48 wt % of the first polycarbonate; 22.49 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 7.76 wt % of the second polycarbonate; 0.38 wt % of the flame retardant; 10.0% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (5) a composition comprising 57.48 wt % of the first polycarbonate; 22.02 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 9.61 wt % of the flame retardant; 10% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (6) a composition comprising 50.45 wt % of the first polycarbonate; 19.05 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 9.61 wt % of the flame retardant; 20% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (8) a composition comprising 57.48 wt % of the first polycarbonate; 22.02 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 1.37% of the second polycarbonate; 8.24 wt % of the flame retardant; 10% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives; (9) a composition comprising 50.45 wt % of the first polycarbonate; 19.05 wt % of the poly(aliphatic ester)-polycarbonate copolymer; 1.37% of the second polycarbonate; 8.24 wt % of the flame retardant; 20% of the glass fiber; 0.50% TSAN and 0.39 wt % of additives.
 16. The article of claim 1, wherein a flame bar comprising the composition demonstrates a probability of first time pass (pFTP) of the UL94 V0 test of 1.0, tested at a thickness of 2.5 mm, 1.5 mm, 1.0 mm or 0.8 mm at 23° C. for 48 hours or 70° C. for 168 hours.
 17. The article of claim 1, selected from electrical and electronic housings, electrical and electronic connectors, automotive connectors, light fixtures, light housings, instrument panels, interior trim, center consoles, panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, fascia, grilles, minor housings, pillar appliqus, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, circuit breakers, running boards, helmet or other protective device, fire helmets, and motor vehicle headlight covers, or any combination thereof.
 18. The article of claim 14, wherein TSAN is present in the composition.
 19. The article of claim 1, wherein the flame retardant comprises potassium perfluorobutane sulfonate.
 20. The article of claim 14, wherein the first polycarbonate comprises structural units derived from 3,3-bis(4-hydroxyphenyl)-2-phenylisoindolin-1-one, and has a weight average molecular weight of 15,500 to 40,000 g/mol, as determined by gel permeation chromatography using Bisphenol A polycarbonate standards; the poly(aliphatic ester)-polycarbonate copolymer has the formula:

 wherein m is 8; and R³ is

the second polycarbonate is a bisphenol A polycarbonate having a weight average molecular weight of 17,000 to 40,000 grams per mole (g/mol), as determined by gel permeation chromatography (GPC) using BPA polycarbonate standards; and the flame retardant comprises at least one of potassium perfluorobutane sulfonate, potassium perfluoroctane sulfonate, tetraethylammonium perfluorohexane sulfonate, potassium diphenylsulfone sulfonate, sodium benzene sulfonate, and sodium toluene sulfonate. 